Tunable actuator joint modules having energy recovering quasi-passive elastic actuators for use within a robotic system

ABSTRACT

A tunable actuator joint module of a robotic assembly comprises an output member and an input member, where the output member is rotatable about an axis of rotation. A primary actuator (e.g., a motor) is operable to apply a torque to rotate the output member about the axis of rotation. A quasi-passive elastic actuator (e.g., rotary or linear pneumatic actuator) comprising an elastic component is tunable to a joint stiffness value and is operable to selectively release stored energy to apply an augmented torque to assist rotation of the output member and to minimize power consumption of the primary actuator. The tunable actuator joint module comprises a control system having a valve assembly controllably operable to switch the quasi-passive elastic actuator between an elastic state and an inelastic state during respective portions of movement of the robotic assembly (e.g., a hip or knee joint of an exoskeleton). Associated systems and methods are provided.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/421,175, filed Nov. 11, 2016, which is incorporated by reference herein in its entirety.

BACKGROUND

A wide variety of exoskeleton, humanoid, robotic arms, and other robots and robotic systems exist, many of which seek the most efficient operation possible. One fundamental technical problem that continues to be a focus is how such systems, such as where energetic autonomy is concerned, can minimize power consumption while still providing acceptable levels of force output. Indeed, power remains an inevitable challenge in the world of robotics. Designers of such systems typically attempt to optimize operation based on the intended use or application. In many cases, either power or efficiency is sacrificed, at least to some extent. For instance, some robotic systems employ high-output power systems that can meet the force output demands of the robotic system, putting this ahead of any efficiency considerations. On the other hand, some robotic systems employ more efficient power systems in an attempt to improve efficiency, with force output being a secondary consideration. High output force or power systems, while capable of performing various tasks, can be costly. Moreover, such systems often are tethered to a power source as portable power remains limited in its capabilities. Efficient, yet low force output systems can lack practicality, inasmuch as many robotic systems are designed to assist humans in work related or other tasks that require a certain level of force in order to perform the task(s). Overall, the power issue has been a challenging obstacle with various efforts being made to maximize output while minimizing power consumption. Even small advances in this ratio of power to output energy consumption area can be highly beneficial. While much research and development is ongoing to improve power sources, another way robotic systems can improve the power to energy output ratio is through the structural build of the robotic system, namely the way various components are configured, how these are controlled, and if the systems can take advantage of naturally occurring phenomenon, such as gravity.

BRIEF SUMMARY OF THE INVENTION

An initial summary of the disclosed technology is provided here. Specific technology examples are described in further detail below. This initial summary is intended to set forth examples and aid readers in understanding the technology more quickly, but is not intended to identify key features or essential features of the technology nor is it intended to limit the scope of the claimed subject matter.

The present disclosure sets forth a tunable actuator joint module of a robotic assembly comprising an output member operable to couple to a first support member of a robotic system, and an input member operable to couple to a second support member of a robotic system. The tunable actuator joint module comprises a primary actuator operable to apply a torque to rotate the output member about an axis of rotation. The tunable actuator joint module comprises a quasi-passive elastic actuator comprising an elastic component dynamically tunable to a joint stiffness value. The quasi-passive elastic actuator is operable to selectively store energy upon a first rotation of the input member, and operable to selectively release energy upon a second rotation of the input member to apply an augmented torque that combines with the torque from the primary actuator to assist rotation of the output member during the second rotation. For example, the quasi-passive elastic actuator can operate in parallel with a primary actuator, such as a motor, wherein the quasi-passive elastic actuator provides the ability to disengage the elastic component (i.e., spring or device/mechanism that exhibits spring-like behavior) during the free swing phase of a gait cycle, but engage the elastic component during certain strategically selective portions of the support phases of the gait cycle (or during other motions of a robotic system) where energy capture and recovery can be exploited to reduce energy in the tunable actuator joint module in the form of reducing primary motor torque and power consumption requirements. In one aspect, the elastic component can comprise a pneumatic gas spring element with active shunting provided by an internal valve assembly (a shunt circuit of the quasi-passive elastic actuator) that provides a lightweight solution for energy recovery by way of its adjustable stiffness (via gas pressure charge) and by way of active engagement and disengagement of its shunt circuit (e.g. via a solenoid or voice-coil actuated valve).

In one example, the tunable actuator joint module comprises or is otherwise operable with a control system operatively coupled to the quasi-passive elastic actuator for selectively controlling application of the augmented torque. In one example, the control system comprises a valve assembly operable to switch the quasi-passive elastic actuator between an elastic state and an inelastic state (i.e., disengaging (closing) and engaging (opening) the shunt circuit, respectively).

In one example, the valve assembly comprises a valve device actuatable to allow or restrict fluid (e.g., air or other gaseous liquids) flow between compression and expansion chambers (gas chambers) of the quasi-passive elastic actuator. In one example, the valve device of the valve assembly is disposed through an opening of a first vane or vane device, wherein the valve device is controllable to open and close the shunt circuit and switch the quasi-passive elastic actuator between the inelastic and elastic states, respectively.

In one example, the quasi-passive elastic actuator, and particularly the elastic component, can comprise a rotary pneumatic actuator. In another example, the quasi-passive elastic actuator can comprise a linear pneumatic actuator. It is noted that the pneumatic actuators can comprise air or any other suitable gas (e.g., nitrogen) as recognized by those skilled in the art. In each of these examples, the elastic component can comprise a housing that is gas pressure charged with a selected gas pressure to define a predefined joint stiffness value.

In one example, the primary actuator can comprise an electric motor that can be operable with a planetary drive transmission rotatably coupled to the electric motor. The planetary drive transmission can be at least partially disposed within a central void of the primary actuator (e.g., electric motor). In one example, a transmission belt can be rotatably coupled between an output pulley of the primary actuator and an input pulley of the rotary pneumatic actuator.

The present disclosure further sets forth a robotic system for a robotic limb configured to recover energy for minimizing power consumption of the robotic system. The system can comprise a plurality of support members and a plurality of tunable actuator joint modules at various joints of the robotic system, each of which can be rotatably coupled to two of the plurality of support members to define a joint of the robotic system. Each tunable actuator joint module comprises: an axis of rotation, the joint defining a degree of freedom; a primary actuator operable to apply a primary torque to cause actuation of the joint; and a quasi-passive elastic actuator comprising an elastic component dynamically tunable to a joint stiffness value and selectively controllable between an elastic state and an inelastic state, the quasi-passive actuator being adapted or operable to store energy upon a first rotation of the joint, and to release energy upon a second rotation of the joint to apply an augmented torque to the joint that combines with the primary torque from the primary actuator to assist rotation of the joint and to minimize power consumption of the primary actuator.

The present disclosure further sets forth a method for operating a robotic system comprising at least one tunable joint module. The method comprises: causing a first rotation of a tunable actuator joint module of a robotic assembly; engaging a quasi-passive elastic actuator of the tunable joint module during the first rotation to store energy; actuating the primary actuator to apply a primary torque and cause a second rotation of the tunable actuator joint module in a different direction from the first rotation, the quasi-passive actuator releasing the stored energy and applying an augmented torque to the primary torque during the second rotation, thereby reducing the power needed by the primary actuator to apply the primary torque to cause the second rotation. The states of the quasi-passive elastic actuator can be controlled by a control system comprising a valve assembly that regulates and controls the flow of gasses within the quasi-passive elastic actuator.

The method can further comprise operating a valve assembly of the control system to engage or open a shunt circuit to selectively disengage operation of the quasi-passive elastic actuator (it enters the inelastic state) of the tunable actuator joint module, and to disengage or close the shunt circuit to engage operation of the quasi-passive elastic actuator in the elastic state.

The method can further comprise actuating a valve device of the valve assembly to open and close the valve assembly (and open or close the shunt circuit).

The method can further comprise generating a predetermined joint stiffness value by gas pressure charging the tunable actuator joint module to a desired or predetermined gas pressure.

The method can further comprise pre-charging the quasi-passive actuator and compressing the elastic component, wherein the stored energy therein can be released at a given time to apply the augmented torque.

The method can further comprise dynamically modifying the predetermined joint stiffness value by changing the gas pressure in the housing.

The present disclosure further sets forth a method of making a tunable actuator joint module. The method comprises configuring a primary actuator, such as a motor, to apply a primary torque about an axis of rotation of a joint of a robotic system to facilitate actuation of the joint within a robot or robotic system about an axis of rotation, and configuring a quasi-passive elastic actuator to be operable with the primary actuator. The quasi-passive elastic actuator can comprise an elastic component dynamically tunable to a joint stiffness value, the quasi-passive elastic actuator being operable to selectively store energy upon a first rotation of the joint, and operable to selectively release energy upon a second rotation of the joint to apply an augmented torque to the primary torque to assist rotation of the joint during the second rotation.

The method can further comprise operably coupling a valve assembly to the quasi-passive elastic actuator. In one example, a valve device can be disposed through an opening of the elastic component in the form of a first vane or vane device. The valve device can be actuatable to allow or restrict gas flow between compression and expansion chambers of the quasi-passive elastic actuator.

The method can further comprise configuring the elastic element with compression and expansion chambers. In one example, the compression and expansion chambers can comprise equal volumes. In another example, the compression and expansion chambers can comprise disparate volumes. In still another example, the compression chamber volume can be greater than the expansion chamber volume.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and advantages of the invention will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example, features of the invention; and, wherein:

FIG. 1 illustrates two positions of a robotic assembly in the form of a lower portion of an exoskeleton having at least one tunable actuator joint module in accordance with an example of the present disclosure;

FIG. 2A is a schematic illustration of a tunable actuator joint module in accordance with an example of the present disclosure;

FIG. 2B is a schematic illustration of a tunable actuator joint module in accordance with an example of the present disclosure;

FIG. 3A is a graph illustrating human weight normalized knee joint torque vs. knee joint angle of a human gait cycle;

FIG. 3B is a graph illustrating the torque required to accomplish a joint trajectory and a portion of a gait where an elastic response can be created by a tunable actuator joint module in accordance with an example;

FIG. 3C is a graph illustrating performance of a tunable actuator joint module in accordance with an example;

FIG. 4A is an isometric view of a robotic assembly, namely a wearable robotic exoskeleton, having at least one tunable actuator joint module in accordance with an example of the present disclosure;

FIG. 4B is an isometric view of the robotic assembly of FIG. 4A;

FIG. 5A is a partial isometric view a tunable actuator joint module for a knee joint of the robotic assembly of FIG. 4A in accordance with an example of the present disclosure;

FIG. 5B is a partial isometric view of the tunable actuator joint module of FIG. 5A from another perspective;

FIG. 6A is an isometric view of a tunable actuator joint module operable with the robotic assemblies of FIG. 1 or 4A, in accordance with an example of the present disclosure;

FIG. 6B is an isometric view of the tunable actuator joint module of FIG. 6A in an actuated position;

FIG. 6C is a front view of the tunable actuator joint module of FIG. 6A;

FIG. 6D is a left side view of the tunable actuator joint module of FIG. 6A;

FIG. 7A is a partially exploded view of the tunable actuator joint module of FIG. 6A;

FIG. 7B is a partially exploded rear view of the tunable actuator joint module of FIG. 6A;

FIG. 8A is a partially exploded view of the tunable actuator joint module of FIG. 6A;

FIG. 8B is a partially exploded front view of the tunable actuator joint module of FIG. 6A;

FIG. 9A is an exploded view of the primary actuator of the tunable actuator joint module of FIG. 6A;

FIG. 9B is a partially exploded front view of the primary actuator of the tunable actuator joint module of FIG. 6A;

FIG. 10A is an exploded view of the quasi-passive elastic actuator of the tunable actuator joint module of FIG. 6A;

FIG. 10B is a partially exploded front view of the quasi-passive elastic actuator of the tunable actuator joint module of FIG. 6A;

FIG. 11A is a cross-sectional view of the quasi-passive elastic actuator of the tunable actuator joint module of FIG. 6A taken along lines 11A in FIG. 10B;

FIG. 11B is a cross-sectional view of the quasi-passive elastic actuator of the tunable actuator joint module of FIG. 6A taken along lines 11A in FIG. 10B, but shown in a rotated state;

FIG. 12A is an isometric view of a the tunable actuator joint module operable with the robotic assembly of FIG. 4A in accordance with an example of the present disclosure;

FIG. 12B is an isometric view the tunable actuator joint module of FIG. 12A;

FIG. 12C is an isometric view the tunable actuator joint module of FIG. 12A;

FIG. 12D is a partial exploded view the tunable actuator joint module of FIG. 12A;

FIG. 12E is an isometric view of the quasi-passive elastic actuator of the tunable actuator joint module of FIG. 12A;

FIG. 12F is an isometric rear view of the quasi-passive elastic actuator of the tunable actuator joint module of FIG. 12A;

FIG. 13A is an isometric view of a tunable actuator joint module operable with the robotic assemblies of FIGS. 1 and 4A in accordance with an example of the present disclosure;

FIG. 13B is a cross-sectional view of the tunable actuator joint module of FIG. 13A taken along lines 13B of FIG. 31A;

FIG. 14A is an isometric view of a first vane device and a second vane device of a quasi-passive elastic actuator of a tunable actuator joint module operable with the any one of the tunable actuator joint modules of FIGS. 5A, 6A, 12A, and 13A, in accordance with an example of the present disclosure;

FIG. 14B is an isometric view of the first vane device and the second vane device of FIG. 14A from another perspective;

FIG. 15A is a cross-sectional view of a valve assembly operable with the first vane device of FIG. 14A in accordance with an example of the present disclosure;

FIG. 15B is a schematic cross-sectional front view of the valve assembly of FIG. 15A operable with the first vane device and the second vane device of FIG. 14A, with the shunt circuit open, in accordance with an example of the present disclosure;

FIG. 15C schematic cross-sectional front view of the valve assembly of FIG. 15A operable with the first vane device and the second vane device of FIG. 14A, with the shunt circuit closed;

FIG. 16A is a cross sectional view (y-plane) of a first vane device (e.g., FIG. 14A) which forms part of a valve assembly in accordance with an example of the present disclosure;

FIG. 16B is a cross sectional view (x-plane) of the first vane device of FIG. 16A;

FIG. 17A is a cross sectional view of a valve assembly operable with the first vane device of FIG. 14A in accordance with an example of the present disclosure;

FIG. 17B is an exploded view of the valve assembly of FIG. 17A;

FIG. 17C is an exploded right view of the valve assembly of FIG. 17A;

FIG. 17D is a cross-sectional view of the valve assembly, in an open position, of FIG. 17A;

FIG. 17E is a cross-sectional view of the valve assembly, in a closed position, of FIG. 17A;

FIG. 18A is an isometric view of a valve assembly operable with the first vane device of FIG. 14A in accordance with an example of the present disclosure;

FIG. 18B is an exploded view of the valve assembly of FIG. 18A;

FIG. 18C is a cross-sectional view of the valve assembly, in an open position, of FIG. 18A;

FIG. 18D is a cross-sectional view of the valve assembly, in a closed position, of FIG. 18A;

FIG. 19 is a graph illustrating performance values for joint damping torque vs. various rotor vane conduit sizes in accordance with an example of the present disclosure;

FIG. 20A is an isometric view of a tunable actuator joint module operable with the robotic assemblies of FIGS. 1 and 4A in accordance with an example of the present disclosure;

FIG. 20B is a right side view of the tunable actuator joint module of FIG. 20A;

FIG. 20C is an isometric view of the tunable actuator joint module of FIG. 20A in an elastic state;

FIG. 20D is a cross-sectional view of an upper section of a portion of the tunable actuator joint module FIG. 20A, showing a valve assembly in an open position;

FIG. 20E is a cross-sectional view of an upper portion of the tunable actuator joint module of FIG. 20A, showing the valve assembly in a closed position;

FIG. 20F is a cross-sectional view of a lower portion of the tunable actuator joint module of FIG. 20A; and

FIG. 21 is a schematic view of a remotely located quasi-passive elastic actuator operable with the robotic assemblies of FIGS. 1 and 4A in accordance with an example of the present disclosure.

Reference will now be made to the exemplary embodiments illustrated, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended.

DETAILED DESCRIPTION

As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is “substantially” enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained. The use of “substantially” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result.

As used herein, “adjacent” refers to the proximity of two structures or elements. Particularly, elements that are identified as being “adjacent” may be either abutting or connected. Such elements may also be near or close to each other without necessarily contacting each other. The exact degree of proximity may in some cases depend on the specific context.

One example of a robotic assembly 100 is generically illustrated in FIG. 1. The robotic assembly 100 is shown in the form of an exoskeleton, and particularly a lower exoskeleton wearable by a user about the lower body. However, this is not intended to be limiting in any way as the concepts discussed herein can be applicable to and incorporated into or implemented with various types of robotic devices, such as exoskeletons (both upper and lower exoskeletons), humanoid robots or robotic devices, teleoperated robots or robotic devices, robotic arms, unmanned ground robots or robotic devices, master/slave robots or robotic devices (including those operable with or within a virtual environment), and any other types as will be apparent to those skilled in the art.

In the example of the robotic assembly 100, the exoskeleton as disclosed herein can be configured as a full-body exoskeleton (i.e., similar to the exoskeleton having both a lower body portion and upper body portion, see FIG. 4A), or as only a lower body exoskeleton (i.e., some or all of the lower body portion), or as only an upper body exoskeleton (i.e., some or all of the upper body portion).

The robotic assembly 100 can comprise a plurality of tunable actuator joint modules having a quasi-passive elastic actuator. The upper extremity quasi-passive elastic actuators can have a different function from the lower extremity quasi-passive elastic actuators, or they can function similarly. For example, the lower extremity quasi-passive elastic actuators can provide an energy recovery mechanism during a portion of cyclic motions such as walking or running, and an ability to swing freely during other parts of the cycle or for other activities. Upper extremity quasi-passive elastic actuators can provide passive gravity compensation when the arms are raised to support armor and/or weapon masses. In both cases, the quasi-passive elastic actuators function to reduce the demand on the power supply, and on the primary actuators that may be used to do work in parallel with the quasi-passive elastic actuators. It is noted that, in example robotic systems, such as those described herein, the types of quasi-passive actuators used within the different joints and corresponding tunable actuator joint modules can be the same or different. Using the example of the robotic assembly 100, different quasi-passive elastic actuators can be used between the upper and lower extremities of the robotic system 100, or between the various tunable actuator joint modules within the upper extremity (the same being the case with the lower extremity), or between various tunable actuator joint modules within the same limb.

The example elastic actuators described herein can be referred to as quasi-passive elastic actuators as they are operable in active and inactive states or modes of operation (as compared to being entirely passive elastic actuators that are always either storing energy or releasing energy during all rotational movements of a joint, or other movements of a mechanical system). In examples discussed herein, the passive and inactive modes or states of operation can be selectable or controllable and even dynamically selectable or controllable (e.g., selectable in real-time), as well as repeatedly switched from one state or mode to another state or mode, during operation of the robotic system. Depending upon the configuration of the tunable actuator joint module, example quasi-passive elastic actuators can comprise a first active state (sometimes referred to herein as an elastic state) in which the quasi-passive elastic actuator can be actuated to store and release energy during various rotations of a joint of the robotic system, a second passive state (sometimes referred to herein as an inelastic state) in which the quasi-passive elastic actuator can be made inactive, such that energy is neither stored nor released during various rotations of the joint, and in some cases a third semi-active or partially active state (sometimes referred to herein as a semi-elastic state) in which the quasi-passive elastic actuator can be partially actuated to store and release energy during various rotations of the joint. In some example robotic systems, the quasi-passive elastic actuator can be switchable between the different modes or states of operation as needed or desired depending on, for example, needed or desired tasks and corresponding rotation movements, various torque or load requirements of the one or more joints of the robotic system, or needed or desired braking forces.

In some examples, the robotic assembly 100 can comprise left and right exoskeleton limbs (note that only the right exoskeleton limb 102 is shown in FIG. 1). The exoskeleton limb 102 can comprise a plurality of support members 104 a-d (e.g., the rigid, structural supports that extend between the joints within the limb of the exoskeleton, or that link the joints together, much like the bones in the human body extending between the joints). The support members 104 a-d can be coupled together for relative movement about a plurality of joints, such as tunable actuator joint modules 106 a-d, defining a plurality of degrees of freedom about respective axes of rotation 108 a-d. The rotational degrees of freedom about the axes of rotation 108 a-d can correspond to one or more degrees of freedom of the human leg. For example, the rotational degrees of freedom about the axes 108 a-d can correspond, respectively, to hip abduction/adduction, hip flexion/extension, knee flexion/extension, and ankle flexion/extension, respectively. Similarly, although not shown, degrees of freedom about respective axes of rotation within an upper body exoskeleton can correspond to one or more degrees of freedom of a human arm. For example, the degrees of freedom about the axes of rotation can correspond to shoulder abduction/adduction, shoulder flexion/extension, shoulder medial/lateral rotation, elbow flexion/extension, wrist pronation/supination, and wrist flexion/extension. A degree of freedom corresponding to wrist abduction/adduction can also be included, as desired.

A human user or operator may use or interact with the exoskeleton robotic assembly 100 (or 101 of FIG. 4A) by interfacing with the robotic assembly 100. This can be accomplished in a variety of ways as is known in the art. For example, an operator may interface with the robotic assembly 100 by placing his or her foot into a foot portion of the assembly, where the foot of the operator can be in contact with a corresponding force sensor. Portions of the human operator can also be in contact with other force sensors of the exoskeleton robotic assembly 100 located at various locations of the robotic assembly 100. For example, a hip portion of the robotic assembly 100 can have one or more force sensors configured to interact with the operator's hip. The operator can be coupled to the robotic assembly 100 by a waist strap or other appropriate coupling device. The operator can be further coupled to the robotic assembly 100 by a foot strap or other securing mechanism. In one aspect, various force sensors can be located about a hip, knee or ankle portion of the robotic assembly 100, corresponding to respective parts of the operator. While reference is made to sensors disposed at specific locations on or about the robotic assembly 100, it should be understood that position or force sensors, or both, can be strategically placed at numerous locations on or about the robotic assembly 100 in order to facilitate proper operation of the robotic assembly 100.

As a general overview, tunable actuator joint modules 106 a-d can be associated with various degrees of freedom of the exoskeleton to provide forces or torques to the support members in the respective degrees of freedom. Unlike traditional exoskeleton systems and devices, the robotic assembly 100 can be configured, such that each tunable actuator joint module is configured to recover energy, which can reduce complexity and power consumption of the robotic assembly 100. For example, the tunable actuator joint module 106 c, which defines a degree of freedom corresponding to a degree of freedom of knee flexion/extension, can be configured to recover energy during a first gait movement and then release such energy during a second gait movement to apply an augmented torque to assist a primary actuator providing a primary torque in rotation of the joint about the degree of freedom (and in parallel with the torque applied by the primary actuator of the tunable actuator joint module 106 c, as discussed below). The tunable actuator joint module 106 c can be selectively controlled, such that the quasi-passive elastic actuator can be engaged (i.e., caused to enter an operating state or condition in which the elastic actuator is operable and enabled to store and release energy (an elastic or semi-elastic state)) and disengaged from operation (i.e., caused to enter an operating state or condition or configuration where it neither stores nor releases energy (an inelastic state)) during joint rotation, or where any previously stored energy can be dissipated or released. In the inelastic state, the joint “freely swings” with negligible resistance to rotate the joint as the operator walks or runs, for instance. By operating in parallel with the primary actuator (e.g., a primary motor operable to actuate the joint), the quasi-passive elastic actuator can provide or apply an augmented torque in parallel with the torque provided by the primary actuator (i.e., a torque that is added to the torque generated by the primary actuator), or a braking force.

The quasi-passive elastic actuator can comprise a compact internal valve, such as a two-way valve, that can be controlled and operated to change the modes of the quasi-passive actuator, namely to switch between an elastic state (where the actuator acts as a spring for transient energy storage and recovery), a semi-elastic state (where the actuator acts as a spring partially compressed), and an inelastic state (where the actuator employs a shunting function that allows the actuator to move freely (i.e., not to store or release energy) (except for friction and movement of fluid through the valve). Moreover, the tunable actuator joint module 106 c can be “tuned” to comprise a desired stiffness, as further discussed below. Thus, the magnitude of stiffness for a given joint is adjustable for mission specific payloads and terrain-specific gaits while the active valve controls exactly when that stiffness is engaged for energy recovery during the support phase and when it is disengaged during the free swinging phase.

The result is effectively a quasi-passive elastic mechanism that, in one advantage, is selectively operable to recover energy (e.g., energy lost during some gait motions) to reduce or minimize power consumption required to actuate the joint. Therefore, when combining a plurality of tunable actuator joint modules within a robotic assembly, such as the lower body exoskeleton shown in FIG. 1, for example, a significant amount of energy can be recovered and utilized during movement (via hip, knee, and ankle joints), which can reduce weight, size, complexity, and overall power consumption of the exoskeleton. A quasi-passive actuator for energy recovery can comprise an elastic component, for example, either a mechanical or pneumatic or hydraulic element, that is capable of storing and releasing energy to the joint, and, optionally, an active switch or clutch capable of engaging and disengaging the elastic component from the primary torque source powering the joint. Implicit in this energy recovery approach is the defining of the magnitude of elastic stiffness, as well as when to engage and disengage the elastic actuator during each gait cycle. These values can be optimized by searching for a stiffness, position offset, and temporal window that minimizes the average of the square of joint torques during the gait cycle. This numerical optimization, in essence, results in minimum average power consumption of a given primary joint torque actuator for a given gait or maneuver. The practical implementation of this approach for energy recovery and reduction of joint actuation torque thus leads to defining that angular stiffness which best works for the majority of time that the robotic assembly is to be used, e.g., walking vs. running, and establishing gait recognition algorithms that can be used to precisely engage and disengage the elastic actuator(s) over a broad range of activities.

The above general overview is explained in more detail below.

FIGS. 2A and 2B each schematically illustrate tunable actuator joint modules in accordance with two examples of the present disclosure. FIG. 2A shows a tunable actuator joint module 120 having a primary actuator 122 operable to provide a primary torque to the tunable actuator joint module 120. In one example, the primary actuator can comprise a geared motor (e.g., a primary actuator having an electric motor operable with a transmission, such as a planetary type of transmission (or any other type of transmission as will be appreciated by those skilled in the art), the primary actuator 122 operating in parallel with a quasi-passive elastic actuator 124 (e.g., a rotary or linear pneumatic (air or other gas) actuator, as will be discussed below), both operable to apply a torque, and in some states a torque in parallel, to a load (e.g., a torque to rotate a joint, or the support members rotatable about one another defining a joint, of a robotic assembly, as in FIGS. 1 and 4A).

The quasi-passive elastic actuator 124 can comprise a valve assembly 126, such as further described below regarding FIGS. 14A-19. The valve assembly 126 can facilitate or can comprise at least part of a control system for the tunable actuator joint module 120, such that it is controllable to selectively facilitate the application of the augmented torque via the quasi-passive fluid actuator 124 in parallel with the torque applied by the geared motor 122.

In examples described herein, “selective” can mean that the tunable actuator joint module can be controlled in real-time at select times and for select durations as needed or desired, such as to vary a magnitude and timing of a braking force, vary a magnitude and timing of compression of the elastic component of the quasi-passive actuator and the storing and releasing of energy therein, or vary a magnitude and timing of a primary torque generated by the primary actuator depending upon different operating conditions, operating states, different demands of the robotic system, or as desired by the operator. Selective control can mean that the quasi-passive elastic actuator can be operated in conjunction with the primary actuator all or some of the time or for a desired duration of time. In addition, “selective” can mean, in examples, that one or more operating parameters or the output performance of the valve assembly can be controlled and varied in real-time as needed or desired. Operating parameters or output performance can include, but is/are not limited to, a magnitude of the augmented torque to be applied, a magnitude of the braking force generated, the stiffness or elasticity of the elastic actuator, the zero or null point of actuation of the elastic actuator, and others.

In examples where the quasi-passive actuator is caused to enter a semi-elastic state or mode of operation, the quasi-passive elastic actuator can be actuated to partially compress the elastic or spring component of the quasi-passive elastic actuator to store, and be enabled to release, an amount of energy or enabled to generate a magnitude of a braking force that is less than what would otherwise be achieved if the quasi-passive elastic actuator were in a fully elastic state. Stated another way, semi-elastic describes that state in which there is a less than 1:1 transfer of energy or forces, due to rotation of the joint, to the quasi-passive elastic actuator coupled between the input and output members (e.g., because the valve assembly is partially open). “Semi-elastic,” as used herein, is not intended to refer to the inherent elastic property (i.e., the elasticity) of the elastic component of the quasi-passive elastic actuator, but merely to a degree of compression of the elastic component.

FIG. 2B is similar to FIG. 2A, except that in this example of a tunable actuator joint module 120′, the primary actuator 122′ comprises a hydraulic actuator incorporated as a powered actuator to operate in parallel with the quasi-passive fluid actuator 124′ of the tunable actuator joint module 120′.

FIG. 3A is a graph showing joint torque vs. joint position as these occur during an example gait of a human, the graph showing the torque (N-m/kg) occurring in the joint relative to or as corresponding to the angle of rotation of the joint. This particular graph is illustrative of an example torque/angular rotation relationship of a human knee (without wearing an exoskeleton), while walking approximately 3 mph on a flat surface. A first gait movement from point A to point B illustrates stance compression following heel strike, a second gait movement from point B to C illustrates stance extension, with the stance phase being completed at point D. A third gait movement between points D, E, F, and A illustrates “double support and leg swing.” Therefore, the “stance phase” is from heel strike (point A) to toe-roll/terminal stance (points A to D), where the torque-joint profile has a quasi-elastic behavior (walking and running are similar regarding this quasi-elastic stiffness). During this phase, the knee also acts as a shock absorber. The “swing phase” is from toe-off to heel strike (points E to A), and during this phase the knee exhibits a quasi-ballistic (passive dynamics) response with some damping during the final extension that occurs before heel strike (thus, the knee acts as a controlled damper or shock absorber).

This characteristic of the human gait is not unique to the knee joint, nor limited to the walking gait, and forms the basis for the tunable actuator joint modules discussed herein. Indeed, when reviewing the joint torque vs. position plots of simulated cyclical exoskeleton activities, such as walking, running, and step climbing, there are periods of time during these specific gait motions where elastic energy recovery can be exploited to reduce the requirement for motor torque to run the joint. Thus, the tunable actuator joint modules described herein can be configured to exploit the features of the natural motion of the hip, knee, and ankle, for instance, to minimize demands on powered actuators (e.g., electric-geared motors) to reduce overall power consumption within the robotics assembly. The tunable actuator joint modules discussed herein can also be incorporated into shoulder and elbow joints, for instance, but these may be more task-specific than as with the lower body joints, as further discussed below. However, the tunable actuator joint modules of lower joints (e.g., hip, knee, ankle) can also be configured to operate based on a specific task (e.g., lifting a load, sitting and standing, and others), rather than just a cyclical operation (e.g., walking or running).

FIG. 3B is a graph showing an exoskeleton knee joint torque (N-m) vs. position (deg.) for walking at 3.5 mph with a 50 lb. payload. The plotted “triangular” labeled line (“joint actuation torque”) represents the required overall torque to accomplish the prescribed joint trajectory, while the plotted “circular” labeled lines (“spring reaction torque”) represents the part of the gait where an elastic response can by created by a quasi-passive elastic actuator of a tunable actuator joint module. Thus, this spring reaction torque can be exploited to reduce power consumption to actuate a joint, as further detailed below.

FIG. 3C is a graph illustrating performance of an exoskeleton having a tunable actuator joint module with a quasi-passive elastic actuator operating in parallel with a primary actuator, the joint module having a joint stiffness of 7 N-m/degree, associated with the human knee joint, in one example. More specifically, the graph shows joint torque (N-m) vs. joint speed (deg./sec) for walking at 3.5 mph with a 50 lb. payload. The plotted “triangular” labeled line (“joint actuation torque”) represents the required overall torque to accomplish the prescribed joint trajectory (e.g., the torque required to rotate a knee), while the plotted “circular” labeled lines (“spring reaction torque”) represents the part of the gait where an elastic response can be created by engaging and disengaging the quasi-passive elastic actuator in a timely manner, as exemplified herein.

As illustrated by this “circular” labeled line, the resulting peak torque is substantially reduced (approximately 25 N-m) vs. the normalized torque requirement (approximately 100 N-m) of the “triangular” labeled line. That is, normally (i.e., without incorporating a tunable actuator joint module having an elastic actuator) the torque requirement is peaked at approximately 100 N-m; however, when incorporating a tunable actuator joint module having an elastic actuator as disclosed herein, the resulting peak torque can be only approximately 20 N-m, thus significantly reducing power requirements for the same gait cycle and operating conditions. This is because the tunable actuator joint module stores energy during a first gait movement (via the quasi-passive elastic actuator), and then releases that energy during a second gait movement to apply an augmented torque that can be applied in parallel with a torque applied by a primary actuator (e.g., a geared motor) of the tunable actuator joint module. Of course, other factors play a role in these results, such as weight, payload, etc. In any event, these graphs illustrate that much less on-board power is required by the powered motor to appropriately actuate a joint when used in conjunction with a selectively controllable quasi-passive elastic actuator, as further exemplified below. The use of a parallel elastic actuator effectively reduces the requirement for motor torque as the elastic actuator is engaged and disengaged in a timely manner, such as during specific phases of a gait cycle. Similar plots or graphs can be shown for hip joints, ankle joints, shoulder joints, and elbow joints. In some cases, the elastic actuator can be engaged full-time for the gaits of these joints.

For the sake of clarity, FIGS. 4A-5B and FIGS. 12A-12F pertain to a first example of a tunable actuator joint module (comprising a quasi-passive elastic actuator in the form of a rotary pneumatic actuator having a rotary pneumatic spring as the elastic component, the quasi-passive actuator being operable in an elastic state, a semi-elastic state, and an inelastic state). FIGS. 6A-11B pertain to a second example of a tunable actuator joint module (comprising a quasi-passive elastic actuator in the form of a rotary pneumatic actuator having a rotary pneumatic spring as the elastic component, the quasi-passive actuator being operable in an elastic state, a semi-elastic state, and an inelastic state). FIGS. 13A and 13B pertain to a third example of a tunable actuator joint module (comprising a quasi-passive elastic actuator in the form of a rotary pneumatic actuator having a rotary pneumatic spring as the elastic component, the quasi-passive actuator being operable in an elastic state, a semi-elastic state, and an inelastic state). FIGS. 14A-15C pertain to an example of a first vane or vane device and a second vane or vane device operable with each of said first, second, and third example tunable actuator joint modules, as well as the case with the example first vane device of FIGS. 16A and 16B. FIGS. 17A-17E pertain to one example of a valve assembly operable with the first vane device of FIGS. 16A and 16B. Similarly, FIGS. 18A-18D pertain to another example of a valve assembly operable with the first vane device of FIGS. 16A and 16B. Finally, FIGS. 20A-20F pertain to another example of a tunable actuator joint module (comprising a quasi-passive elastic actuator in the form of a linear pneumatic actuator having a linear pneumatic spring as the elastic component, the quasi-passive actuator being operable in an elastic state, a semi-elastic state, and an inelastic state). The following discussion will cross-reference relevant Figures accordingly.

FIGS. 4A and 4B show isometric views of an exemplary robotic assembly 101 in the form of an exoskeleton wearable or usable by a human operator. The robotic assembly 101 could alternatively be a humanoid robot, or other robotic assembly as discussed above. As shown, the robotic assembly 101 can be configured as a full-body exoskeleton (i.e., an exoskeleton having both a lower body portion and an upper body portion). However, this is not intended to be limiting as the exoskeleton can comprise only a lower body exoskeleton (i.e., some or all of the lower body portion), or only an upper body exoskeleton (i.e., some or all of the upper body portion).

The robotic assembly 101 can comprise left and right exoskeleton limbs. The right exoskeleton limb 103 can comprise a plurality of lower body support members 105 a-d. The support members 105 a-c can be coupled together for relative movement about a plurality of respective joints 107 a-c defining a plurality of degrees of freedom about respective axes of rotation. The right knee joint 107 c can comprise a tunable actuator joint module 109 a having a quasi-passive elastic actuator, as described herein. It will be appreciated, although not detailed herein, that the hip joint 107 a can also comprise a tunable actuator joint module having a quasi-passive elastic actuator, as described herein. The ankle joint 107 d can also comprise a tunable actuator joint module, such as described below regarding FIGS. 20A-20F. The left exoskeleton limb can be similarly configured, as shown.

FIGS. 5A and 5B show close up, partial front and rear perspective views of the tunable actuator joint module 109 a of FIG. 4A (with the support member 105 b that supports the tunable actuator joint module 109 a being hidden; but see FIGS. 4A and 4B, 12A and 12B). The particular tunable actuator joint module 109 a of FIG. 5A will be specifically described regarding FIGS. 12A-12F.

The robotic assembly 101 of FIGS. 4A-5B can have the same or similar features as described generally with reference to FIG. 1. For example, the tunable actuator joint module 109 a, which defines a degree of freedom corresponding to extension/flexion of a knee joint, can be configured to recover energy during a first gait movement and then release such energy during a second gait movement to apply an augmented torque to rotate the knee joint about the degree of freedom in parallel with a torque applied by a primary actuator of the tunable actuator joint module 109 a, similarly as discussed above. Moreover, the tunable actuator joint module 109 a can be selectively controlled to be disengaged from operation (i.e., inelastic by neither storing nor releasing energy) via a control system (e.g., a valve assembly), such that the joint “freely swings” with negligible resistance to rotate the joint as the operator walks or runs, for instance. And similarly, the tunable actuator joint module 109 a can be “tuned” to define a predefined joint stiffness value, as further discussed below.

FIGS. 6A-11B illustrate various aspects of a tunable actuator joint module 130 according to an example of the present disclosure, which can be incorporated into a robotic assembly or system to comprise and define a joint as discussed herein. Although the tunable actuator joint module 130 in the present disclosure will be specifically focused as providing hip and/or knee joints of a robotic assembly this is not intended to be limiting in any way as those skilled in the art will recognize that similar concepts can be incorporated into a tunable actuator joint module configured for use in a different joint of the robotic system. For instance, the tunable actuator joint module 130 can readily be incorporated as the module 109 a of FIG. 4A, with slight modification of the output member, as discussed below. Note that the tunable actuator joint module 130 is shown inverted for purposes of illustration clarity, yet it would readily be incorporated in the orientation as exemplified by the tunable actuator joint module 109 a of FIG. 5A.

The tunable actuator joint module 130 comprises a primary actuator 132 and a quasi-passive elastic actuator 134 structurally coupled to each other, and operable with one another to provide torque to the joint. An input member 136 a and an output member 136 b (of the quasi-passive elastic actuator 134) can each rotate about an axis of rotation 137 (e.g., corresponding to an axis of rotation and corresponding degree of freedom of a human joint, such as the knee or hip joint). As shown, both the input and output members 136 a and 136 b can rotate about the same (collinear) axis of rotation 137; however, this is not meant to be limiting because the input and output members 136 a and 136 b could have different axes of rotation if positioned along different axes of rotation and operably coupled together. The primary actuator 132 (e.g., a geared electric motor) is operable to apply a torque to the output member 136 b for rotation about the axis of rotation 137, and the quasi-passive elastic actuator 134 (e.g., a rotary pneumatic actuator) is selectively operable to generate a braking force, or to apply an augmented torque to the output member 136 b along with the torque applied by the primary actuator 132 to actuate the joint, such as during a certain portion of a gait movement.

More specifically, the quasi-passive elastic actuator 134 is operable or controllable by a control system (e.g., a valve assembly) to selectively store energy or to selectively generate a braking force (in an elastic state or a semi-elastic state) upon a first rotation of the input member 136 a, and to selectively release that energy (while still in the elastic or semi-elastic state) during a second or subsequent rotation of the input member 136 a. In the elastic and semi-elastic states, the quasi-passive elastic actuator 134 can be enabled to generate a braking force to resist rotation of the joint, or to apply an augmented torque to the output member in parallel with the torque applied by the primary actuator 132 (as further detailed below), or both. Those skilled in the art will recognize that these different states of operation of the quasi-passive elastic actuator can entered into during rotation of the input member, and the joint, that is in the same or a different direction.

With respect to the elastic state of the quasi-passive actuator as it operates to store and release energy, in one aspect, the first rotation of the input member 136 a can be achieved via active actuation of the primary actuator to actuate the tunable joint module and to cause rotation of the joint module (and any structural supports coupled thereto). In another aspect, the first rotation of the input member 136 a can be achieved passively, namely by exploiting any available gravitational forces or external forces acting on the robotic system suitable to effectuate rotation of the input member 136 b within the tunable actuator joint module (e.g., such as a lower exoskeleton being caused to perform a sitting or crouching motion, which therefore affects rotation of the various tunable joint modules in the exoskeleton). The exploiting of such gravitational forces by the quasi-passive actuator in parallel with a primary actuator provides the tunable joint module with compliant gravity compensation. Once the energy is stored, it can be released in the form of an augmented torque to the output member 136 b, or it can be used to brake or restrict further rotation.

The quasi-passive elastic actuator 134 can further be configured, upon a third or subsequent rotation(s), to neither store nor release energy, the quasi-passive elastic actuator 134 being caused to enter an inelastic state. In this inelastic state, the input and output members 136 a and 136 b are caused to enter a “free swing” mode relative to each other, meaning that negligible resistance exists about the quasi-passive elastic actuator 134 (this is so that the actuator 134 does not exhibit a joint stiffness value that would restrict rotation of the input member 136 a relative to the output member 136 b, such as would be desired during a leg swing phase of a gait cycle of the robotic device). In this manner, the quasi-passive elastic actuator 134 is switchable between the elastic state and the inelastic state, such that the quasi-passive elastic actuator 134 applies an augmented toque (in the elastic state) in parallel with a torque applied by the primary actuator 134. This combined torque functions to rotate the output member 136 b relative to the input member 136 a in a more efficient manner as less torque is required by the primary actuator to perform the specific gait phase, thereby reducing the power requirements/demands of the primary actuator 134, as further detailed below.

In one example, the quasi-passive elastic actuator 134 can be structurally mounted to the primary actuator 132 by a first mounting plate 138 a and a second mounting plate 138 b, each positioned on either side so as to constrain the primary and secondary actuators 132 and 134 in a “sandwich” state (see FIGS. 7A-8B). The first mounting plate 138 a is mounted to a housing mount 140 of the primary actuator 132 via a plurality of fasteners 142 (with spacers there between). The first mounting plate 138 a comprises a primary aperture 144 a (FIG. 8B) that rotatably supports a collar bearing 146 of the primary actuator 132, and comprises a secondary aperture 144 b that rotatably receives a collar bearing 148 (FIG. 8B) supported by the quasi-passive elastic actuator 134.

The second mounting plate 138 b is mounted to the other side of the housing mount 140 via a plurality of fasteners 151, and comprises an input aperture 152 that rotatably supports a collar bearing 154 (FIG. 8A) coupled to the quasi-passive elastic actuator 134. Therefore, collectively the input aperture 152 of the second mounting plate 138 b and the secondary aperture 144 b of the first mounting plate 138 a are sized to structurally support the quasi-passive elastic actuator 134 and to facilitate rotation of the quasi-passive elastic actuator 134 via the collar bearings 148 and 154 supporting either side of the quasi-passive elastic actuator 134.

The input member 136 a can be a load transfer component that can comprise many different shapes and forms, depending upon the particular application (e.g., exoskeleton, humanoid robot, robotic hand or arm), and depending on the support member attached to the input member 136 a (e.g., such as support member 105 b of FIG. 4A). As such, the specific configurations shown are not intended to be limiting in any way. In the present example, the input member 136 a can comprise a horizontal flange 156 and a rotary interface aperture 158 (FIGS. 7A and 8A). The horizontal flange 156 can be received and seated against a horizontal step portion 160 of the second mounting plate 138 b to restrict movement of the input member 136 a relative to the second mounting plate 138 b, and thereby relative to the housing mount 140 of the primary actuator 134. The rotary interface aperture 158 can be coupled to an input interface member 162 of a first vane device 164 (see FIGS. 10A and 10B) that extends through the input aperture 152 of the second mounting plate 138 b. The input member 136 a can comprise a robotic support member interface portion 166 coupleable to a support structure of a robotic assembly, such as the support member 105 b of FIG. 4A.

The output member 136 b can be a load transfer component that can comprise many different shapes and forms, depending upon the particular application (e.g., exoskeleton, humanoid robot, robotic hand or arm). As such, the specific configurations shown are not intended to be limiting in any way. In the present example, the output member 136 b can comprise an actuator interface portion 168 secured to a housing 170 of the quasi-passive elastic actuator 134 via fasteners (not shown). Alternatively, the output member 136 b can be formed as an integral part of the housing, and be disposed closer to the axis of rotation 137, such as described below regarding FIGS. 12A-12E, and shown in the example exoskeleton of FIGS. 4A-5B.

The output member 136 b can comprise a robotic support member interface portion 172 coupleable to a support structure of a robotic assembly, such as the exoskeleton of FIG. 4A. Therefore, as the quasi-passive elastic actuator 134 rotates about the axis of rotation 137, the output member 136 b (and its associated support member) concurrently rotates with the attached housing 170 about the same axis of rotation 137.

With regards to the primary actuator 132 (see particularly FIGS. 9A and 9B with the primary actuator 132 shown in an exploded view), can comprise a housing mount 140. The housing mount 140 comprises a first mount structure 174 a and a second mount structure 174 b coupled to each other via fasteners 176. The first and second mount structures 174 a and 174 b are fastened together to house and structurally support many of the components of the primary actuator 132. For instance, the primary actuator 132 comprises a motor 178 that is seated in respective annular recesses of the first and second mount structures 174 a and 174 b. The motor 178 can be a high-performance Permanent Magnet Brushless DC motor (PM-BLDC), which can be a variant of a frameless torque motor with winding optimized to achieve the desired maximum torque and speed while operating using a 48 VDC supply and a high-performance COTS controller, such as motor MF0127-032 marketed by Allied Motion. Controlling a brushless electric motor is well known and will not be discussed in detail, but it will be appreciated that any number of control schemes can be used in combination with the motor and sensors associated with the tunable actuator joint module 130 to operate the motor. The motor described above and shown in the drawings is not intended to be limiting in any way. Indeed, other motors suitable for use within the primary actuator 132 are contemplated herein, as are various other types of actuators, such as hydraulic actuators.

The motor 178 can comprise a stator 180 and rotor 182 rotatable relative to each other (in a typical fashion for commercially available frameless brushless motors). The motor 178 can be configured to comprise a central void 184 about the central area of the motor 178 and surrounded by the rotor 182. Advantageously, a transmission, such as the planetary transmission 186, can be positioned and supported within (entirely or partially) the central void 184. This provides a low-profile geared motor state with high torque output for a relatively small electric motor, as exemplified below. It should be appreciated that the planetary transmissions exemplified herein can be replaced (or supplemented with) other transmission types, such as harmonic, cycloidal, worm, belt/chain, crank, four-bar linkage, backhoe linkage, bell crank, continuously variable, or any others as will be recognized by those skilled in the art. These other types of transmissions are not detailed herein as those skilled in the art will recognize how these may be implemented without undue experimentation.

Planetary transmissions are well known and will not be discussed in great detail. However, in the present example the planetary transmission 186 can be configured as a 4:1 geared planetary transmission. Thus, in one example the planetary transmission 186 can comprise an outer ring 190 engaged to four planet gears 188 (one labeled) mounted about a carrier 192, whereby the four planet gears 188 have gear teeth that engage with the gear teeth of a central sun gear 194 (FIG. 9B). With planetary transmissions generally, the stationary component can be any one of the outer ring 190, or the carrier 192, or the sun gear 194, for instance, whereby the other two components are rotatable relative to the chosen stationary component.

In the present example, the outer ring 190 is stationary, as it is fastened to the first mount structure 174 a via fasteners (not shown) through apertures 196 around the outer ring 190 and into threaded bores 197 in the first mount structure 174 a. A rotatable transfer wheel 198 (FIG. 9A) is disposed on an outer side of the primary actuator 132 adjacent the second mount structure 174 b, and is fastened to a drive collar 200 via perimeter fasteners 202. The drive collar 200 is fastened or fixed to the rotor 182 of the motor 178. The transfer wheel 198 is operable to transfer rotation from the rotor 182 of the motor 178 to the sun gear 194 about the axis of rotation 203 (FIG. 8A). A spacer sleeve 201 can be positioned adjacent the drive collar 200 and between the outer ring 190 of the planetary transmission 186 and the rotor 182 to act as a support spacer between the planetary transmission 186 and the rotor 182.

The transfer wheel 198 can comprise a central aperture 204 that supports a transfer hub 206 that is fastened to the transfer wheel 198 via fasteners 208. The transfer hub 206 can have inner gear teeth (not shown) that can be engaged with outer gear teeth of the sun gear 194. Therefore, upon applying an electric field to the motor 178, the rotor 182 rotates about axis 203, which causes the transfer wheel 198 to rotate, which thereby causes the sun gear 194 to rotate, all in a 1:1 ratio. Upon rotation of the sun gear 194 about axis of rotation 203, the planetary gears 188 rotate around the sun gear 194, which causes the carrier 192 to rotate. An output shaft 209 is secured to a central portion 211 of the carrier 192, such that rotation of the carrier 192 causes rotation of the output shaft 209 about axis 203, which provides a 4:1 geared-down transmission arrangement from rotation of the rotor 182 to the output shaft 209 via the planetary transmission 186. Other planetary transmission types and gear reduction schemes can be used instead of a 4:1 transmission, such as a 3:1 or a 2:1 (or even greater ratios) planetary gear scheme.

To reduce build height, the planetary transmission 186 can be positioned inside of the rotor 182 of the motor 178. Depending on the motor selected, the inside diameter of the rotor will dictate the maximum outside diameter of the planetary transmission. Once the planetary ring has been constrained by its outside diameter, there are a limited amount of options for gear ratios and output torques available. The output ratio is determined from the ratio of the number of teeth on the ring gear to the number of teeth on the sun gear. To obtain a higher reduction in the compact design of the planetary unit, the sun gear diameter can be reduced, which generally corresponds to less power transmission. The capacity to transmit higher torques is reduced with a smaller sun gear. A balance of reduction and strength can be determined for a planetary unit that will physically fit inside the motor rotor. By implementing a helical cut gear, higher forces can be transmitted on the gear teeth making the unit stronger. A wider tooth will also improve the load carrying capacity of the sun gear, however this increases the weight as well.

In addition, the sun gear 194 makes contact with several teeth simultaneously so the contact ratio is much higher than a conventional spur gear transmission. Another benefit of planetary gears is the fact that the transmission is in-line with the motor, which allows for compact mounting states. Two of the 4:1 planetary units (one shown on FIG. 9B) can be nested together to produce a 16:1 final drive, for instance.

Thus, in one example using Allied Motion's MF0127-032 motor, it has an inside diameter of 3.3 inches, which means that a planetary transmission of approximately 3.15 inches (or less) could be used and disposed in the central void of the motor. And, Matex's 75-4MLG12 planetary transmission can be incorporated, which is a 4:1 unit with a 2.95 inch outside diameter having a 118 N-m peak torque, weighing just 500 grams. Such planetary transmission could be incorporated with a brushless motor as discussed herein to generate a compact configuration. Therefore, in the illustrated example of FIG. 9B, the output shaft 209 applies a relatively higher torque at a low speed with very little noise and backlash via the planetary transmission 186, all in a compact form because the planetary transmission 186 is housed within the void 184 of the brushless frameless electric motor 178, for instance. It is noted that the specific types of motors and planetary transmissions described herein are not intended to be limiting in any way, as will be recognized by those skilled in the art.

With continued reference to FIGS. 9A and 9B, a free end 210 of the output shaft 192 extends through an aperture 212 of the first mount structure 174 a. A tapered support collar 214 surrounds and is coupled to the output shaft 192 (a key and slot interface can be used to couple the support collar 214 to the output shaft 192). The tapered support collar 214 has an outer tapered surface that mates to an inner tapered surface of a primary pulley 216 (e.g., such as a Morse taper interface) to couple the output shaft 192 to the primary pulley 216 (a key and slot interface can be used to couple the support collar 214 to the primary pulley 216). A first collar bearing 218 a is positioned within the aperture 212 (FIG. 9A) of the first mount structure 174 a to rotatably support the output shaft 192, and a second collar bearing 218 b is positioned with an outer end of the primary pulley 216 to rotatably support the free end 210 of the output shaft 192.

In one example, a sensor plate 220 can be fastened to an outer side of the second mount structure 174 b, and has an aperture that supports a position sensor 222. The position sensor 222 is adjacent the transfer wheel 198, which has an aperture through to the sun gear 194 to allow the position sensor 222 to determine the position of the sun gear 194, which can ultimately determine the rotational position of the output shaft 209, thereby providing the angular position of a knee or hip joint, for instance. The position sensor 222 can be any suitable sensor, such as a 13-bit hall-effect sensor. Additional positions sensors can be coupled to the system, and utilized to ultimately determine the position of the joint. As discussed above regarding the graphs of FIGS. 3B and 3C (and below regarding the valve assembly), the particular position of the knee joint is relevant in determining and controlling actuation of a valve assembly to switch the tunable actuator joint module between the inelastic and elastic or semi-elastic states (e.g., engage and disengage the elastic actuator), or to dynamically vary a zero point or position of the elastic actuator, as further discussed below.

Referring back to FIGS. 6A-8B, upon rotation of the output shaft 209 (in either rotational direction) by operating the motor 178, the primary pulley 216 rotates a transmission belt 224 that is coupled to the quasi-passive joint actuator 134 (as further discussed below) to provide a primary torque to rotate the tunable actuator joint module 130 to rotate the knee joint, for instance. The transmission belt 224 can be a Gates Poly Chain GT Carbon synchronous belt, or other suitable belt A belt tensioning device 225 (FIGS. 7B and 8B) can be adjustably slidably coupled to a slot of the first mounting plate 138 a via a fastener, which is operable by a user with a tool to slide the belt tensioning device 225 toward or away from the belt 224 to tighten or loosen the belt 224, as desired. In some examples, various other torque-transmitting devices can replace the particular configuration of the belt 224, such as one or more belts or linkages or gears or tendons or others (or combinations of such). The torque-transfer device can be arranged to have an axis of rotation that is offset (e.g., oriented in a direction along a plane that is perpendicular or orthogonal or some other angle) to the axis of rotation 203 of the primary actuator 132 (or some other angle other than parallel). And, various transmissions can be arranged to provide different gear reductions from input to output, including a relatively high gear reduction (e.g., 20:1, or more), or a relatively low gear reduction (e.g., 1:1), or any gear reduction between these, depending on the particular application. In some examples, the torque-transmitting device in the form of belt 224, or such various alternative torque-transmitting devices, can allow the primary actuator 132 to be remotely located away from the output (i.e., the primary actuator 132 is located a given distance away from the output of the tunable actuator joint module, but operably connected thereto via the torque-transmitting device), wherein the remotely located primary actuator 132 can be actuated and its torque transferred to the output of the tunable actuatable joint module corresponding to a joint of the robotic system. For instance, the primary actuator 132 could be located at a lower back area of an exoskeleton (e.g., FIG. 4A), while such alternative torque-transmitting device(s) could transfer the primary toque from the lower back area to an output member located in the tunable actuator joint module for the hip joint for actuating the hip joint.

With regards to the quasi-passive elastic actuator 134 (particularly with reference to FIGS. 10A and 11B), the quasi-passive elastic actuator 134 is operable to apply an augmented or supplemental torque (e.g., to the output member 136 b, which can be fixed to a support member, such as a robotic support member). The input member 136 a and the output member 136 b can each be rotatable about the axis of rotation 137 (or rotatable about different axes). Notably, the axis of rotation 137 is substantially parallel to the axis of rotation 203 of the primary actuator 132 (see FIG. 7A). This contributes to the compact nature of the tunable actuator joint module 130 because the primary actuator 132 and the quasi-passive elastic actuator 134 are vertically positioned, or stacked, relative to one another (e.g., see FIGS. 6A-6D), which locates substantially all of the mass of the tunable actuator joint module 130 proximate or near the axis of rotation 137 of the joint (i.e., about the input and output members 136 a and 136 b).

In one example, the quasi-passive elastic actuator 134 can comprise a rotary pneumatic (e.g., or other) actuator having a rotary pneumatic spring as the elastic component that is selectively operable (e.g., engageable and disengageable at select times and for select durations) to apply an augmented torque to the output member 136 b along with the torque applied by the primary actuator 132, or to generate and apply a braking force. The quasi-passive elastic actuator 134 can be made selectively operable via control of a valve assembly associated with the elastic actuator 134 (discussed further below). The quasi-passive elastic actuator 134 is operable to selectively store energy (elastic state) upon a first rotation of the input member 136 a, and to selectively release energy (elastic state) upon a second rotation of the input member 136 a to apply an augmented torque to the output member 136 b in parallel with the torque applied to the output member 136 b by the primary actuator 132, where the release of the energy and the augmented torque are caused to occur at phases, or portions of phases, of the gait cycle that exhibit an elastic response (see FIG. 3A). The quasi-passive elastic actuator 134 is further configured, upon a third rotation, to neither store nor release energy (inelastic state) about the quasi-passive elastic actuator 134. Likewise, a braking force can be generated during certain operating scenarios where it may be desirable to brake or restrict, to some degree, rotation of the joint. The braking force can be applied to restrict rotation when the primary actuator is inactive, but rotation of the input member and joint are still occurring (e.g., in response to an external force), but this is not intending to be limiting as the braking force can be applied at a time when the primary torque is being applied to the output member from the primary actuator.

The housing 170 of the quasi-passive elastic actuator 134 can comprise a housing body 226 and a faceplate 228 fastened together via a plurality of fasteners 230, and that collectively define a cavity 232 (FIG. 10B) of the housing 170. A first vane or vane device 164 and a second vane or vane device 229 are supported by the housing 170 and rotatable relative to each other about the cavity 232. The input interface member 162 of the first vane device 164 extends through a central aperture 234 of the faceplate 228 (and through the input aperture 152 of the second mounting plate 138 b (see FIG. 7A)).

The input interface member 162 is rotatably supported about the faceplate 228 by a collar bearing 236. The collar bearing 236 is held in position by a ring 241 fastened to the faceplate 228. The input interface member 162 comprises key slots 238 disposed radially around the input interface member 162, and that receive keys/rods (not shown) that interface with corresponding key slots formed internally about a central aperture 240 of the input member 136 a.

Opposite the input interface member 162 of the first vane device 164 is a cylindrical stabilizing portion 242 (FIG. 10A) that extends through a central aperture 244 of the chamber body 226, and is rotatably supported to the housing 170 by a collar bearing 246 that surrounds the annular stabilizing portion 242. The collar bearing 246 can be seated in an outer recess of the housing body 226. A ring 248 can be fastened to the housing body 226 to retain the collar bearing 246 about the housing body 226. The collar bearing 148 surrounds an outer annular member 250 of the housing body 226 and is rotatably interfaced with the secondary aperture 144 b of the first mounting plate 138 a (see FIG. 7B) to rotatably support the housing body 226 with the mounting plate 138 a.

With continued reference to FIGS. 10A and 10B, and with reference to FIGS. 14A-14B, the first vane device 164 can be a unitary or uniform body that comprises a cylindrical body portion 252 and an elongated vane 254 extending from the cylindrical body portion 252. In one example, the second vane device 229 can comprise an elongated vane positioned such that it extends approximately 180 degrees from the elongated vane 254 of the first vane device 164 when in a nominal position (FIG. 11A). The second vane device 229 can be fixed to the housing body 226 and the faceplate 228 by a pair of pins 258 (FIG. 10B) that extend laterally through either end of the second vane device 229. The pair of pins 258 extend into receiving bores of the housing body 226 and the faceplate 228. Thus, the second vane device 229 is fixed to the housing 170, such that rotation of the housing 170 about the axis of rotation 137 causes concurrent rotation of the second vane device 229 relative to the first vane device 164 (see e.g., comparison and discussion of FIGS. 11A and 11B). In this manner, the second vane device 229 has an interface surface 260 that slidably engages the outer surface 262 of the cylindrical body portion 252 of the first vane device 164 (FIG. 14A).

As can be appreciated from FIGS. 11A and 11B, the first vane device 164 and the second vane device 229 define a compression chamber 264 a and an expansion chamber 264 b (as also defined by the boundaries of the cavity 232 of the housing 170). The location of the second vane device 229 relative to the first vane device 164 can define the volume of these chambers. In one example, the second vane device 229 can be located 180 degrees from a 0 degree position of the first vane device 164, wherein the compression and expansion chambers 264 a and 264 b, respectively, comprise the same volume, as shown on FIG. 11A. Note that the cross sectional view of FIG. 11A is inverted relative to the position shown on FIG. 10B. The second vane device 229 can be located relative to the first vane device 164 at other positions so as to provide or define compression and expansion chambers having disparate volumes, or in other words different volume ratios, when the quasi-passive elastic actuator is in the inelastic state or mode (that facilitating free-swing). Furthermore, the elastic component can be pre-charged prior to the first rotation, such that a pressure differential exists between the compression chamber and the expansion chamber.

The cavity 232 (i.e., the compression and expansion chambers 264 a and 264 b, respectively) of the housing 170 can be gas pressure charged to a nominal pressure (e.g., approximately 1500 psi) via a valve 269 (FIG. 10B), such that both chambers 264 a and 264 b have equalized gas pressure when the first vane device 164 is at its nominal position (the position of the rotor vane relative to the second vane device when the quasi-passive elastic actuator is in the inelastic mode just prior to entering the elastic mode) (e.g., 180 degrees relative to the second vane device 229, 90/270 degrees relative to the second vane device 229, and others) (and when the valve assembly is open, as discussed below). A compression chamber valve 267 a and an expansion chamber valve 267 b (FIG. 10B) are each in fluid communication with respective compression and expansion chambers 264 a and 264 b to facilitate removing or adding an amount of gas pressure in each or both chambers as desired to generate a particular spring stiffness value. In some example, this spring stiffness value can be dynamically modified by the operator while in the field of use. For instance, a person or operator wearing an exoskeleton may desire a stiffer knee joint when performing a particular task or carrying a certain load. Accordingly, the nominal gas pressure in the cavity 232 can be dynamically tuned or modified in real-time and in the field by removing or adding gas pressure within the housing 170 via the valves, thus permitting a variable joint stiffness value within the quasi-passive elastic actuator. This is an advantage over systems that have a manufactured spring stiffness that is not modifiable by a user. In any event, the quasi-passive elastic actuator can be pre-charged with a pre-charge pressure to comprise a predetermined joint stiffness value. In some examples, “pre-charge” refers to injecting or introducing pressurized gas (i.e., above ambient) into both the compression and expansion chambers 264 a and 264 when the first and second vane devices are at their nominal positions (e.g., 180 degrees relative to each other, in the above example). Therefore, the higher the pre-charge pressure (e.g., 200 psi vs. 1646 psi), then the greater the spring stiffness value for a particular actuator joint module, because a greater gas pressure would result in a particular compression chamber when pre-charging with a higher gas pressure with the same amount of rotation of the first vane device relative to the second vane device, when comparing the resulting compression chamber pressure of differing pre-charge gas pressure values. This is one example of what is meant by the term “tunable” actuator joint module, because the example actuator joint modules discussed herein can be tuned to have a particular joint stiffness value by selecting the amount of gas pressure charged in (or removed from) the chambers of the actuator joint modules, as will be appreciated by the examples and discussion herein.

Upon rotation of the input member 136 a relative to the output member 136 b about the axis of rotation 137 (e.g., in the counter clockwise direction of FIG. 11B), the quasi-passive elastic actuator can be engaged so as to cause the first vane device 164 to rotate (e.g., the first vane device 164 can be caused to rotate approximately 90 degrees, for instance (in practice, the rotation may be more or less than 90 degrees)). Such rotational movement can be the result of a gait movement, external forces, or other type of movement, that causes a first support member to rotate about a second support member, such as between the points A to B of FIG. 3A. That is, the input and output members 136 a and 136 b would rotate relative to each other, as being secured to respective first and second support members of a robotic assembly, for instance (e.g., FIG. 4A). Accordingly, upon such rotation, gas (e.g., air, nitrogen, carbon dioxide, argon, Freon, a mixture of gases, etc.) within the compression chamber 264 a can be compressed between the first vane device 164 and the second vane device 229, thereby storing energy therein, as illustrated in FIG. 11B (the compressed gas exhibiting spring-like behavior). And, upon a second gait movement, such as between points B to C of FIG. 3A, the input member 136 a is initiated to rotate relative to the output member 136 b in the opposite direction (i.e., clockwise direction) (again, rotating in the opposite direction is not required as energy can be stored and released during rotation in the same direction in other examples). Accordingly, with the elastic actuator engaged (either still engaged, or engaged selectively at a later time), compressed gas in the compression chamber 264 a expands, thereby releasing stored/potential energy harvested during the first rotation or gait movement. This expanding gas pushes or causes a biasing force to the elongated vane 254 of the first vane device 164. As a result, a torque is exerted by the first vane device 164 relative to the second vane device 229 to rotate the second vane device 229 and the attached housing 170, which consequently applies the augmented torque to the output member 136 b. Notably, during rotation of a particular joint module, the spring stiffness of the joint module is varied because of the nonlinear manner (with the valve assembly in the fully closed position) in which energy is stored when continually compressing gas in a compression chamber. Thus, the spring stiffness will vary through the various degrees of compression and expansion cycles as the quasi-passive elastic actuator is actuated during various degrees of rotation of the joint module and corresponding joint.

In some examples, the manufactured position of the second vane device 229 can be selected at a certain position to achieve a desired elastic response. For instance, the second vane device 229 can be fixed to the housing 170 at less than or greater than 180 degrees relative to the elongated vane 254 of the first vane device 164, thus increasing or decreasing the disparity between the expansion and compression volumes, or in other words, providing different and unequal compression and expansion chamber volumes. This can be advantageous for users having differing knee heights and differing gait types, or for task-specific movements, such as crouching and jumping where knee joint rotation may be greater than merely walking or running. Moreover, locating the second vane device 229 at different positions relative to the first vane device 164 when the valve assembly is closed can produce linear or nonlinear responses or output. With disparate compression and expansion chamber volumes, the differential pressure can evolve more rapidly, particularly when the expansion chamber volume is relatively small, since the volume ratio is higher than the compression side for the same rotor rotation. This means that a lower charge pressure can be implemented to attain the same pneumatic spring stiffness as would be obtained if the volumes were equal.

For example, assume in one non-limiting example that the second vane device 229 is initially positioned 90 degrees relative to the first vane device 164 (see FIG. 11B as a reference to show such possible initial position), and that the total volume of the housing body 226 is approximately 137 cc. Accordingly, the compression chamber 264 a can comprise a larger volume (e.g., approximately 108 cc) than the expansion chamber (e.g., approximately 29 cc). The pre-charge pressure of the compression and expansion chambers 264 a and 264 b can be approximately 1646 psi, thereby producing an 1854 psi peak at 20 degrees rotation, which produces 140 N-m of torque. This pre-charge pressure of 1646 psi can accomplish a targeted joint stiffness of 7 N-m/deg. Positioning the second vane device 229 in a position other than 180 degrees apart relative to each other provides disparate expansion and compression chamber volumes, which maintains lower charge and actuation pressures (as compared to the “180 degree” positioning example and substantially equal volumes) because the first vane device 164 requires about half the rotational movement to achieve the same amount of energy storage about the compression chamber 264 a as compared to if the volumes were equal. This can also reduce or minimize the size and weight of a particular quasi-passive elastic actuator because a smaller chamber volume is possible. This is another example of what is meant by the term “tunable” actuator joint module, because the example actuator joint modules discussed herein can be tuned to have a particular joint stiffness value by selecting the initial or starting position of the second vane device 229 relative to the first vane device 164, as will be appreciated by the examples and discussion herein.

In one example, as shown in FIGS. 14A and 14B (and with continued reference to FIGS. 4A-11B), a pair of small ring seals 259 can each be disposed on either side of the first vane device 164 to seal gas from transferring between (or exiting) the compression and expansion chambers 264 a and 264 b, respectively. Likewise, another pair of larger ring seals 261 can each be disposed on either side of the cylindrical body portion 252 to seal gas from transferring between the chambers 264 a and 264 b, thereby providing two stages of sealing. The elongated vane 254 can have a seal member 263 positioned through a slot extending through a central area of the vane 254 to seal gas from transferring between chambers 264 a and 264 b. Likewise, the second vane device 229 can also comprise a seal member 265 disposed in a groove around the perimeter of the second vane device 229 to seal areas of contact around the second vane device 229 on all four vertical/lateral sides.

As discussed above, the primary actuator 134 can be operated to apply a primary torque (along with the augmented torque) to rotate the output member 136 b about axis of rotation 137. In this manner, a splined ring gear 268 can be coupled to the housing body 226 via keys 270 (FIG. 10A) that mate the splined ring gear 266 about an annular interface portion 272 of the housing body 226. The splined ring gear 266 can be rotatably coupled with the primary pulley 216 (of the primary actuator 134) via the transmission belt 224. Therefore, upon the desired or selected second gait movement, the quasi-passive actuator 134 applies the augmented torque concurrently with the torque of the primary actuator 134 to actuate the tunable actuator joint module 130 about the axis of rotation 137. Because the torque applied by the primary actuator 132 is supplemented with the augmented torque applied by the quasi-passive elastic actuator 134, the motor 178 can be selected from a group of smaller motors (e.g., having less power dissipation) than would otherwise be needed within a joint module not having an elastic actuator for accomplishing the same task or function of the robotic assembly, which further contributes to the compact configuration of the module 130.

For instance, the motor 178 can be a Brushless DC motor (BLDC), such as a Permanent Magnet BLDC sold by Allied Motion (MF0127-032) having a 95 mm outside diameter and a 32 mm think frameless motor with torque in the range of 40 to 60 N-m, and peak torque as large as 90 N-m, and with winding optimized to achieve the desired maximum torque and speed while operating using a 48 VDC supply and a high performance COTS controller. The motor coils can be rated for operation up to 130 deg. C., so the motor may be able to operate continuously while running even at ambient temperature as high as 50 to 60 deg. C. (122 to 140 deg. F.), but ideally at a steady state temperature of approximately 40 degrees C. above ambient. Of course, this is only one specific example that is not intended to be limiting in any way.

In one example of power usage, assume a lower body exoskeleton (e.g., FIG. 4A) includes left and right hip joints for flexion/extension, and knee joints for flexion/extension, where each of these joints comprises a tunable actuator joint module as discussed herein. While walking at approximately 3.5 mph, the total power usage to actuate each hip joint is approximately 90 W per gait cycle, while operating at approximately 40 degrees C. above ambient. And, the total power usage to actuate each knee joint is approximately 70 W per gait cycle, while operating at approximately 60 degrees C. above ambient Thus, the total average power for two exoskeleton legs (while walking) is approximately 320 W (i.e., 90+90+70+70). Therefore, the energy used per meter while walking is approximately 213 J/m (or a travel distance of approximately 17 km/kW-hr used).

While running at approximately 6 mph, the total power usage to actuate each hip joint is approximately 150 W per gait cycle, while operating at approximately 70 degrees C. above ambient And, the total power usage to actuate each knee joint is approximately 145 W per gait cycle, while operating at approximately 60 degrees C. above ambient Thus, the total average power for two exoskeleton legs (while running) is approximately 590 W.

These same two example operating conditions (walking and running) can be achieved with a tunable actuator joint module weighing approximately 5.08 kg (or less depending on material choices and other variables), and having a max torque of 300 N-m for the primary actuator (e.g., motor and one planetary transmission). The maximum torque for the quasi-passive elastic actuator (i.e., that which applies an augmented torque) can be 460 N-m for a hip joint (with a 645 psi pre-charge), and 350 N-m for a knee joint (with a 1525 psi pre-charge). These results are with a maximum speed of 600 degrees/second for each hip and/or knee joint. In some examples, the pre-charge pressure can be up to 3000 psi, with a burst pressure of 5000 psi or less. Note that the ankle joints can have the performance results discussed below regarding the linear pneumatic actuator of FIGS. 20A-20F.

In some examples, a second transmission, such as a second planetary transmission, can be incorporated with the primary actuator 132 to provide further gear reduction. For instance, a low or high drive second planetary transmission could be coupled to the output (e.g., carrier) of the planetary transmission 186, and the output of the second planetary transmission could be coupled to the output shaft 210. Thus, such cascaded planetary transmissions and the transmission belt 224 can provide a three stage gear reduction from the original output torque and speed of the motor 178.

In the example illustrated in FIGS. 6A-10B, the planetary transmission 186 can be a 4:1 transmission with the belt 224 providing a 2.05:1 transmission reduction (as a result of the larger diameter of the gear ring 268 and the smaller diameter of the output pulley 216, as discussed above). The resulting ratio gear reduction from the motor 178 to the output member 136 b can be 8.2. In an example where the motor 178 is a 48V motor (and Allied Motion's motor mentioned above), the maximum output torque can be approximately 342 N-m, and the maximum output speed can be 1008 degrees/second. This example is not meant to be limiting in any way. In another example, the belt 224 can provide a 1:1 transmission reduction, or it can vary from this ratio. Likewise, the planetary transmission can be a 3:1 or a 5:1 (or even greater ratios), as mentioned above. As will be recognized by those skilled in the art, and similar to the first transmission discussed above, other types of transmission types can be incorporated and used as a second transmission. In some examples, other frameless, brushless motors (or other types of primary actuator types (e.g., hydraulic, pneumatic)) can be incorporated, as discussed above, to generate a maximum output torque that is greater or less than 342 N-m, and greater or less than a maximum output speed of 1008 degrees/second, depending on the particular requirements of the joint to be actuated.

FIGS. 12A-12F show various views of the tunable actuator joint module 109 a, as exemplified in FIGS. 4A-5B as an actuator for a knee joint of a robotic assembly. The support member 150 b (FIGS. 4A and 5A) can structurally support the tunable actuator joint module 109 a by being fastened or otherwise secured or coupled to the tunable actuator joint module 109 a, such as to mounting plates 338 a or 338 b or both. The support member 150 b can comprise an opening 301 that receives and supports other structural support members, such as an exoskeleton as shown in FIGS. 4A and 5A. The tunable actuator joint module 109 a can have substantially all the same components and functionality as described above regarding the tunable actuator joint module 130, except that the output member 336 b of the quasi-passive elastic actuator 134 is formed as part of the housing 370, as best shown in FIG. 12E. Either way, the input member 336 a and the output member 336 b rotate about axis 107 c, as in FIGS. 4A and 12A.

It should be appreciated that many of the components and functionality of the tunable actuator joint module 130 described above regarding FIGS. 6A-11B can be readily incorporated with the tunable actuator joint module 109 a of FIGS. 12A-12F. To this end, FIGS. 12A-12F will not be discussed in great detail; however, the same components are labeled in FIGS. 12A-12F as corresponding to the same components of the tunable actuator joint module 130 of FIGS. 6A-11B.

Thus, the quasi-passive elastic actuator 134 and the primary actuator 132 are operative to apply a torque to rotate the input member 136 a relative to the output member 336 b, which can rotate support member 105 c (FIG. 4A) relative to support member 105 b, for instance. Or, the quasi-passive elastic actuator 134 can be operable to apply a braking force to restrict rotation of the input member 136 a relative to the output member 336 b. Note that the only substantive difference between the example of FIGS. 12A-12F and the example of FIGS. 6A-11B is the fact that the output member 336 b is formed as part of the housing body 226 of the housing 170 (as opposed to coupled to and extending from the housing body 226, as shown with output member 136 b regarding FIGS. 6A-11B). In this manner, output member 336 b can be coupled to one side of support member 150 c (FIG. 5A), and input member 336 can be coupled to the other side of support member 150 c (FIG. 5B). Although not shown in FIGS. 12A-12F, the quasi-passive elastic actuator 134 can support a first vane device (e.g., 164), second vane device (e.g., 229), and a valve assembly (discussed below) disposed through the first vane device, and controllable to switch the quasi-passive elastic actuator 134 between inelastic and elastic states, similar to or the same as the quasi-passive elastic actuator of FIGS. 6A-11B.

Notably, the quasi-passive elastic actuator 134 can be positioned laterally adjacent a human knee joint (while wearing the exoskeleton of FIG. 4A), such that the axis of rotation 107 c is at or near the axis of rotation of the human knee joint. This can minimize the moment of inertia of one support member 105 b relative to the coupled adjacent support member 105 c because the axis of rotation 107 c is positioned at or near the axis rotation of the human knee joint, so less work/power is required as compared to exoskeleton joints that are not positioned at or near the axis of rotation of the human knee joint. This also positions the mass of the tunable actuator joint module 130 near the axis of rotation of the human knee joint, which can also assist to minimize the power requirements of the primary actuator to actuate the joint module 130 because less work/power is required to actuated the tunable actuator joint module 130 as compared to exoskeleton joints having a mass positioned distally away from the axis of rotation of the human knee joint.

FIG. 13A shows another example of a quasi-passive elastic actuator 500, and FIG. 13B shows a vertical cross sectional view of the quasi-passive elastic actuator 500 along lines 13B-13B of FIG. 13A. The quasi-passive elastic actuator 500 is similar to and can function in a similar manner as the quasi-passive elastic actuator 134 of FIG. 6A (and the quasi-passive elastic actuator 109 a of FIG. 5A), such that it is operable with a primary actuator (e.g., 132) to apply an augmented torque to actuate a tunable actuator joint module (not shown herein, but see, for example, the tunable actuator joint modules 109 a, 130 discussed above), or to apply a braking force to restrict rotation of the input member relative to the output member within the tunable actuator joint module, as described herein. As such, the above discussion can be referred to in understanding the quasi-passive elastic actuator 500. The quasi-passive elastic actuator 500 can comprise a first housing body 502 a rotatably coupled to a second housing body 502 b, and defining a cavity 503 that can be pressurized to a desired gas pressure (as described above). A first vane device 504 can be rotatably supported on either end by each of the housing bodies 502 a and 502 b. An output member 506 can be coupled to an output end of the first vane device 504.

The second housing body 502 b can operate as an input member (e.g., as part of, or coupled to, a robotic support member), and can be coupled to the other end of the first vane device 504. A second vane device (not shown here, but similar to FIG. 10B) can be coupled to the first housing body 502 a and can be operable with the first vane device 504, such as is described above, with respect to FIGS. 10A-11B. The output member 506 can be coupled to a support member, which can be coupled to, or be part of, a robotic support member (e.g., a lower leg member). An annular ring gear 510 can be secured to the first housing body 502 a, and can be coupled to a primary actuator (e.g., 132) via a transmission belt (e.g., belt 224).

Therefore, similarly as described above regarding the tunable actuator joint module 130, upon rotation of the input member in the form of the second housing body 502 b relative to the output member 506 about an axis of rotation 512, the first vane device 504 can be caused to rotate. Such rotational movement can be the result of a gait movement of a robotic assembly, such as between points A and B of FIG. 3A. That is, the input and output members can rotate relative to each other, as being secured to respective first and second support members, for instance (e.g., see FIG. 4A). Accordingly, upon such rotation, gas within a gas compression chamber (e.g., 264 a of FIG. 11B) is compressed between the first vane device 504 and the second vane device (e.g., 229), thereby storing energy therein (or generating a braking force). Upon a second gait movement, such as between points B to C of FIG. 3A, the input member in the form of the second housing body 502 b is initiated to rotate relative to the output member 506, such as in the opposite direction (again, rotation may be in the same or different directions). Accordingly, compressed gas in the gas compression chamber expands to release potential energy stored therein. This expanding gas pushes or causes a force to be exerted on an elongated vane 514 of the first vane device 504. As a result, a torque is exerted by the first vane device 504 relative to the second vane device (e.g., 229) to rotate the first housing body 502 a and to apply an augmented torque to the output member 506 that supplements the torque provided by the primary actuator to rotate the input and output members during the second gait movement.

During such second gait movement, a primary actuator (e.g., 132) rotates the transmission belt, which rotates the annular ring 510 to apply a primary torque to rotate the first housing body 502 a, which exerts a torque to rotate the output member 506. The first vane device 504 can comprise an opening 516 that can support and receive a valve assembly to selectively control operation of the quasi-passive elastic actuator 500, as further detailed below. As such, and although not shown here, the quasi-passive elastic actuator 500 can comprise a valve assembly similar to those described herein.

With reference to FIGS. 10A-11B, and particular reference to FIGS. 14A-19, discussed are various valve assemblies that can be incorporated with any of the quasi-passive elastic actuators discussed herein (e.g., 109 a, 134, 500). The following description of such valve assemblies will be described with reference to each of their respective figures, as well as FIGS. 10A-11B, which describe and illustrate the exemplary tunable actuator joint module 130 and the quasi-passive elastic actuator 134, these being included in the description for the sake of simplicity and clarity, although they are intended only as one example of a joint module capable of implementing any one of the valve assemblies discussed below and shown in FIGS. 14A-19.

As taught herein, the tunable actuator joint module 130 can be switchable between an elastic state, a semi-elastic state, and an inelastic state with the assistance of a control system operatively coupled to the quasi-passive elastic actuator 134 for selectively controlling application of the augmented torque or the braking force (e.g., during selective portions of a gait cycle, during a lifting task, during a climbing task, in response to an external load acting on the robotic system (including gravity), or during other movements by a robotic device or system). The control system can comprise any one of the valve assemblies discussed herein, a first vane device (e.g., see first vane device 164), and a controller (not shown) for controlling operation of a particular valve assembly. The controller can be part of a computer system on-board the robotic system, such as onboard an exoskeleton, or remotely located, such as could be the case in a teleoperated or humanoid type of robotic system, for instance. The valve assemblies can comprise pneumatic valves operable to switch the mode of operation of the quasi-passive elastic actuator, such as between that of a spring (valve closed), that which facilitates free swing of a limb (valve opened) or that of a damper or brake (valve partially opened).

Each of the valve assemblies provides or facilitates a “clutch” or “brake” type of capability that permits gas to transfer (i.e., shunt) back and forth between the compression and expansion chambers, via what is termed a shunt circuit, when the valve assembly is opened, or partially opened, and for gas to be restricted and compressed to provide a compress the elastic component, when the valve is closed, or partially closed, such as to provide controlled damping or braking when the valve is partially opened or partially closed. The shunt circuit can be defined, at least in part, by the flow pathways of the gas between the quasi-passive actuator and one or more of its components, including the valve assembly and one or more of its components. Different valve assemblies can comprise different flow paths, and thus differently configured shunt circuits. As such, the quasi-passive actuator can comprise a shunt circuit that can be opened (the elastic component is caused to enter the inelastic state), closed (the elastic actuator is caused to enter the elastic state), or partially opened (causing the elastic actuator to enter the semi-elastic state to act as a damper and/or brake) by the selective and variable control or operation of the valve. Spring stiffness is a function of piston (first vane device) and chamber geometries, as well as gas pressure charge. Thus, the magnitude of stiffness for a given joint is adjustable, such as for mission specific payloads and terrain-specific gaits while the active valve controls exactly when that stiffness is engaged for energy recovery during the support phase and when it is disengaged during the ballistic or free swinging phase. The valve assemblies discussed herein provide the tunable joint module with the ability to rapidly vary the characteristics of the quasi-passive actuators between that of a near free joint to that of a nominally linear elastic element (when opened or partially opened). This results in power operation of the joints of the robotic system (e.g., shoulder, elbow, hip, knee and ankle joints) that is relatively low compared with prior joints that do not have a quasi-passive elastic actuator.

The valve assemblies discussed herein can be operated and controlled to be closed, thereby facilitating application of an augmented torque, regardless of whether the primary actuator is operated to apply a primary torque. Thus, the term “augmented” is not meant to be limited to applying a supplemental or additional torque with the primary torque, because the augmented torque may be the only torque applied to actuate a particular clutched joint module. For instance, after an exoskeleton's upper body is used to lower a load (thereby storing energy about quasi-passive elastic actuators associated with joint modules of the upper body), and after the load is released by the upper body, the arms of the upper body may be moved upwardly and back to a normal position only by virtue of the “augmented torque” being applied by the associated quasi-passive elastic actuators. This is because the primary actuator may not be needed to move the arm back up to a normal position because the stored energy is sufficient for such purpose. Moreover, during such application of “only” applying the augmented torque, the associated valve assemblies can be variably controlled to desired positions (e.g., partially opened) to provide a damping force or braking force to control the speed or rate at which the respective quasi-passive elastic joint modules move, as discussed elsewhere herein. Of course, for the same movement, such can also be applied in addition to a primary torque provided by the primary actuator.

Moreover, in some examples, the valve assemblies discussed herein can be located and operable at a joint of the robotic system. In one example, the valve assembly can be supported within an opening of the first vane device of the quasi-passive elastic actuator, such that the valve is integrated into or positioned through the first vane device (and particularly within the first vane shaft), and supported in a position about an axis of rotation of the tunable actuator joint module, and particularly the quasi-passive elastic actuator. In this position, the valve assemblies can comprise an axis of actuation that is parallel, and in some cases, collinear, with the axis of rotation of the tunable joint module (and a joint of the operator in some robotic systems, such as with an exoskeleton). The axis of actuation can comprise an axis of rotation in those cases where the valve device of the valve assembly is rotatable in a bi-directional manner to open and close the valve assembly, or an axis of translation in those cases where the valve device is translatable in a bi-directional manner to open and close the valve assembly.

FIGS. 15A-15C illustrate a valve assembly 604 operable with a first vane device 600 (similar to the first vane device 164 described above) in accordance with one example. In this example, the first vane device 600 comprises an opening or bore 602 extending through a central area of the first vane device 600 and along an axis of rotation 137. The valve assembly 604 comprises a valve device 606 disposed within the opening or bore 602 of the first vane device 600. The valve device 606 can comprise at least one cylindrical portion (i.e., a portion having a cylindrically configured surface) positioned through the opening 602, which interfaces with a corresponding inner cylindrical surface of the opening 602. Of course, a cylindrical cross-sectional configuration is not intended to be limiting in any way, particularly in the example configuration in which the valve device 606 translates relative to the first vane device 600. In one example, the valve device 606 can be situated about the axis of rotation 137, or at least have a portion that intersects the axis of rotation 137.

The first vane device 600 can define, at least in part, a valve body of the valve assembly 604. In this manner, the first vane device 600 can comprise a first conduit 605 a in fluid communication with a compression chamber 610 a (e.g., 264 a of FIG. 11A), and a second conduit 605 b in fluid communication with an expansion chamber 610 b (e.g., the expansion chamber 264 b of FIG. 11A), such that, in at least one operating state, gas can be caused to move between the compression chamber 610 a and the expansion chamber 610 b through, and as controlled by, the valve assembly 604 (a portion of which assembly comprises the first vane device 600). These described fluid flow paths comprise and define a part of the shunt circuit that exists between the compression and expansion chambers and the valve assembly.

The valve assembly 604 can comprise a valve actuator 612, such as a voice coil or other solenoid or electric actuator, operatively coupled to the valve device 606 to facilitate selective actuation (i.e., movement) of the valve device 606. The valve actuator 612 can actuate the valve device 606 by rotating it or by axially moving it about or relative to the opening or bore 602. Thus, the valve assembly 604 and the valve device 606 comprises an open or partially open position (FIGS. 15A and 15B) that permits at least some fluid flow (i.e., the shunting of fluid) between the compression and expansion chambers 610 a and 610 b. The valve device 606 further comprises a closed position (FIG. 15C) (when actuated by the actuator 612) that restricts or blocks fluid flow between the compression and expansion chambers 610 a and 610 b.

More specifically, the valve device 606 comprises at least one opening 614 through the valve device 606 that can be selectively positioned between an open, partially open, and a closed position. With the valve device 606 in an open position or partially open position, the opening 614 is aligned, at least in part, with the first and second conduits 605 a and 605 b so as to facilitate fluid communication between the compression and expansion chambers 610 a and 610 b via the respective conduits 605 a and 605 b (e.g., to open or partially open the shunt circuit, where the valve assembly functions to try to equalize pressure between the compression and expansion chambers 610 a and 610 b), as shown in FIGS. 15A and 15B. In the inelastic state with the shunt circuit open where gas pressure is equalized, and where there is little to no resistance to movement of the first vane device 600 relative to the second vane device 603 (i.e., gas is free to move between the compression and expansion chambers through the valve assembly as the tunable joint module is rotated), the quasi-passive elastic actuator 601 neither stores nor releases energy in the form of an augmented torque to the tunable actuator joint module 130, nor does it generate a braking force. Rather, the quasi-passive elastic actuator is in free swing mode where the first vane device 600 is freely rotatable relative to the second vane device 603, and where negligible resistance (or reduced resistance) is generated between the first vane device 600 and the second vane device 603 (and consequently negligible resistance from the quasi-passive actuator is transferred to the first and second support members rotatably coupled about the quasi-passive elastic actuator 601).

Thus, keeping with the discussion above regarding FIGS. 11A and 11B, the valve assembly 604 can be selectively controlled so that it is maintained in an open position where the shunt circuit is maintained in an open position, such that no torque assistance is provided to the primary actuator (except in cases where the valve is variably controlled in a partially open position where some residual torque exists as a damping or braking torque). In other words, the tunable actuator joint module 130 can function with only the primary actuator providing any needed torque input, or in response to an external force (e.g., an impact force, momentum or gravity that induces rotation) during a free swing mode. For example, during a portion of a gait movement, such as is desired between points D-A (FIG. 3A), the valve assembly 604 of the quasi-passive actuator can be opened (i.e., inactive) to open the shunt circuit, and to allow free swing of a joint of a robotic joint of a robotic exoskeleton, for instance.

Conversely, as illustrated in FIG. 15C, the valve device 606 can be positioned in the closed position, thereby closing the shunt circuit. In the closed position, the quasi-passive elastic actuator 601 (e.g., 109 a, 134, 500) is operable in the elastic state and is active to store energy and to release energy to the tunable joint actuator module. That is, the valve device 606 is actuated (e.g., rotated or translated) by the valve actuator 612 to a closed position, such that the opening 614 formed in the body of the valve device 606 is brought out of alignment with the conduits 605 a and 605 b, so as to restrict fluid communication between the compression and expansion chambers 610 a and 610 b via the respective conduits 605 a and 605 b, thereby closing the shunt circuit. Thus, in this closed position, the quasi-passive elastic actuator 301 functions to store energy in the form of compressed gas pressure, and then to release the stored energy when needed in the form of an augmented torque that supplements the torque provided by the primary actuator to the tunable actuator joint module. As explained above regarding the discussion pertaining to FIGS. 11A and 11B, during a first portion of a gait movement or gait cycle, the valve device 606 can be closed so as to cause the quasi-passive actuator to store energy as the primary actuator inputs a torque to cause the tunable actuator joint module to rotate to carry out the first portion of the gait cycle. During this rotation, the rotator vane device is displaced as discussed above. Upon completion of the first portion of the gait cycle, a second portion of the gait cycle, where rotation of the tunable actuator joint module is in the opposite direction, can take advantage of the stored energy in the form of an augmented torque that is applied in the same direction as the torque input by the primary actuator, the augmented torque generated as the compressed gas attempts to place the first vane device and the second vane device in equilibrium. Indeed, both the storing and release of energy occurs with the valve assembly 604 in the closed position of FIG. 15C to engage or actuate the quasi-passive actuator. Although not shown, the valve device 606 of the assembly 604 can be placed in a position so as to partially open the shunt circuit, wherein rotation of the joint causes the quasi-passive elastic actuator 301 to be partially actuated to store (and in some cases to also release) some energy that can be applied to the joint as a braking force.

It is further noted that the valve device 606 can be, in some examples, strategically positioned about an axis of rotation 137 of the tunable actuator joint module and the robotic joint. For example, where the valve device 606 is rotated by the valve actuator 612, the valve device 606 (or at least a component of the valve device 606) has an axis of rotation that is congruent or parallel with the axis of rotation 137 of the robotic joint. Likewise, in examples where the valve device 606 is axially translated through the opening 602, the valve device 606 comprises an axis (such as an axis of translation) parallel or collinear with the axis of rotation 137 of a robotic joint (and in some cases with the joint of an operator, such as an operator operating an exoskeleton).

As discussed, in some examples, the valve assembly 604 and valve device 606 can be controlled to actively dampen rotation of a particular tunable actuator joint module. More specifically, the valve device 606 can be variably controlled to multiple different positions, between the opened and closed positions, that place the joint module, and particularly the quasi-passive elastic actuator, in a semi-elastic state, so that the compression and expansion chambers are in fluid communication with each other to some degree (e.g., the valve device being 10 percent, 20 percent, 50 percent, 75 percent “open”). In examples, this semi-elastic state or “damping state” of the quasi-passive elastic actuator can provide a corresponding active braking or damping force to selectively store and recover some degree of energy as desired. In the example shown, a controlled signal can be transmitted to the actuator 612 to variably control the rotational position of the valve device 606. For example, during the free swing phase the valve device 606 can be moved to a position such that the opening 614 is not completely in the open position as shown in FIG. 15B; rather, it may be rotated slightly to be partially open so that some fluid flows through the opening 614, thereby at least partially actuating the quasi-passive elastic actuator to provide a controlled damping feature or damping mode to restrict or damp absolute free movement of a particular joint module. This “active damping” can also be advantageous in task-specific movement of the robotic system, such as when lowering a load. For example, with a load being carried by an upper exoskeleton, the valve devices of the elbow and/or shoulder tunable actuator joint modules can be actively and variably controlled to a position that provides damping to control (i.e., slow down) the downward movement of the arm supporting the load. It will be appreciated that the position of the various valve device examples discussed herein can also be variably controlled between the open and closed positions in this manner to provide a controlled damping or braking force or component.

It should be noted that valve assembly (and the shunt circuit) can be also be partially opened during the release of energy from the quasi-passive actuator in order to smoothen an output response. In other words, with the joint module configured to release energy stored by the quasi-passive actuator, the valve assembly can be partially opened and the quasi-passive actuator placed in the semi-elastic state or damping mode during the release of such energy, such that the output response can be made less nonlinear, and in some cases made linear, than would otherwise be the case if the valve assembly were to be fully closed. The degree to which the valve assembly (and the shunt circuit) can be opened and the timing of this is controllable in real-time during any rotation of the joint module.

FIGS. 16A-17E illustrate a valve assembly operable with a first vane device in accordance with another example. In this example, a valve assembly 654 can comprise a valve device 656. At the outset, the valve device 656 can comprise the same or similar features described above regarding valve device 606. Moreover, the valve assembly 654 is shown as being operable with the specific first vane device 164 described above (see FIGS. 16A and 16B).

The first vane device 164 can comprise a portion of the valve assembly 654, or in other words, the first vane device 164 can form a part of or can comprise a component of the valve assembly 654. In one example, the first vane device 164 can define, at least in part, a valve housing configured to house and facilitate operation of the valve device 656. Specifically, the first vane device can comprise a first channel 288 a formed annularly about an opening or bore 277 formed through a central area of the first vane device 164. The first vane device 164 includes a compression chamber conduit 290 a (see also FIGS. 14A and 14B) that can be in fluid communication with a compression chamber as discussed herein. Similarly, a second channel 288 b is formed annularly about the opening 277 and includes an expansion chamber conduit 290 b (see also FIG. 14B) that can be in fluid communication with an expansion chamber as discussed herein.

The valve device 656 can be disposed and operably situated within the opening 277 of the first vane device 164, wherein the opening, and the walls defining the opening, function as a valve housing for the valve device 656 (and any other corresponding components of the valve assembly). In this example, the valve device 656 comprises a movable valve component 657 coupled to a valve actuator 662, such as by one or more fasteners 651. The valve actuator 662 can comprise a piston 663 and an actuator device 665, such as a voice coil. The actuator device 665 can be electrically coupled to a power source and a controller (not shown) to electrically control the actuator device 665 to axially move the piston 663 along the axis of rotation 137 of the first vane device 164, for instance. Therefore, the valve actuator 662 is configured to axially move the movable valve component 657 between open, partially open, and closed positions.

The valve device 656 further comprises a first valve body 659 adjacent and in support of the movable valve component 657. The first valve body 659 comprises an outer annular channel 661, and a plurality of fluid openings 664 formed through the first valve body 659 radially around the outer annular channel 661. The first valve body 659 can comprise interface portions 668 a and 668 b on either side of the outer annular channel 661, which can each support seals 666 that function to seal off gasses, the interface portions 668 a and 668 b and the seals 666 being operable to engage and interface with the inner surface defining the opening 277 of the first vane device 164.

The plurality of fluid openings 664 are each configured to be in fluid communication with the second channel 288 b of the first vane device 164 (see FIG. 17D), which second channel 288 b is in fluid communication with an expansion chamber via the conduit 290 b, as discussed above. As shown in FIG. 17A, the first valve body 659 can be generally cylindrically shaped and can comprise a central opening 672 through which the movable valve component 657 translates axially, as discussed below.

The valve device 656 further comprises a second valve body 667 adjacent and engaged with the first valve body 659. The second valve body 667 can be formed generally as a cylindrically shaped cap member disposed within and interfaced with the opening 277 of the first vane device 164. At one end, the second valve body 667 can comprise an interface portion 670 that interfaces with or mates to the first valve body 659, and at the other end a cap portion 669 that seals off an inner chamber area 679 defined by the various components of the valve assembly 654. The second valve body 667 comprises an outer annular portion 671 that has a plurality of fluid openings 673 formed radially around the outer annular portion 671. The second valve body 667 can comprise an interface portion 675 adjacent the outer annular portion 671, which can help support a seal 677 to seal off gasses. The plurality of fluid openings 673 are each in fluid communication with the first channel 288 a of the first vane device 164 (FIG. 17D), which is in fluid communication with a compression chamber via the conduit 290 a, as discussed above.

As shown in FIGS. 17A and 17D, the valve device 656 is in the open position, specifically showing the movable valve component 657 retracted by the piston 663, which exposes or uncovers the plurality of openings 663 of the first valve body 659. Thus, the openings 664 are in fluid communication with the openings 673 of the second valve body 667 about chamber 679, which thereby places the conduits 290 a and 290 b in fluid communication with each other, which thereby places the compression and expansion chambers (e.g., 264 a and 264 b, FIG. 11A) in fluid communication with each other, thereby equalizing pressure between chambers of the quasi-passive elastic actuator when in the inelastic state, as discussed herein. Such open position can facilitate free swing mode of a robotic joint, for instance, as discussed above.

As shown in FIG. 17E, the valve device 656 is in the closed position, specifically showing the movable valve component 657 extended by the piston 663 (upon actuation), which blocks or covers the plurality of openings 664 of the first valve body 659. In this position, the openings 664 are not in fluid communication with the openings 673 of the second valve body 667, which thereby restricts fluid flow between the conduits 290 a and 290 b, which thereby restricts fluid flow between the compression and expansion chambers (e.g., 264 a and 264 b, FIG. 11A). The result is that the quasi-passive elastic actuator is placed in the elastic state to store energy or release energy, as discussed above. Although not shown, the valve device 656 can be positioned in the partially open position to place the quasi-passive actuator in the semi-elastic state.

Notably, the openings 664 and 673 are formed radially around the perimeters of the respective valve bodies 659 and 667. This configuration provides a radial balance of gas pressure about the first and second valve bodies 659 and 667, and also about the movable valve component 657, because an equal amount of gas pressure is passing through the openings 664 and 673 around the entire perimeter of the first and second valve bodies 659 and 667. This tends to result in equal or balanced gas pressure being exerted radially about the movable valve component 657, which reduces friction when the movable valve component 657 is actuated between the open and closed positions. Providing radial gas pressure balancing can reduce the amount of generated heat at a given speed at which the movable valve component 657 is actuated. In one example, the movable valve component 657 can switch between the open and closed positions in less than 15 milliseconds, or even less than 10 milliseconds. This is advantageous when it is desirable to quickly switch the quasi-passive elastic actuator between inelastic, semi-elastic, and elastic states, such as when a user is running while wearing an exoskeleton. This also maximizes or improves the efficiency of the quasi-passive elastic actuator because it reduces the likelihood that the quasi-passive elastic actuator is engaged or disengaged at an improper time that is counterproductive to the actual movement occurring about the joint of the robotic device.

In addition to the radial gas pressure balancing feature, the valve assembly 654 can also be axially gas pressure balanced. That is, the movable valve component 657 can comprise a cylindrically shaped tube body that has at least one fluid opening 675 in constant fluid communication with a first chamber 677 (shown adjacent the piston 663; FIG. 17D) and a second chamber 679, whether in the open or closed positions. That is, the at least one fluid opening 675 is formed through the movable valve component 657 adjacent the first chamber 677, which is defined by an inner surface of the first vane device 164. And, second chamber 679 is defined by in the inner surfaces along both of the movable valve component 657, the first valve body 659, and the second valve body 667. Thus, regardless of whether the valve assembly 654 is in the closed position, partially opened position, or the opened position, there is continuous fluid communication between at least one fluid opening 675, the first chamber 677, and the second chamber 679, such that gas is not compressed or expanded about the first and second chambers 677 and 679 when switching between the open, partially open and closed positions. Thus, pressure is equalized between the first and second chambers 677 and 679 as the movable valve component 657 is axially moved between the open and closed positions, which equalization prevents gas pressure from being exerted against the movable valve component 657 in either axial direction (as discussed above) during switching the quasi-passive elastic actuator between inelastic and elastic states. Similar in principle to the radial gas pressure balancing discussed above, this axial gas pressure balancing tends to result in equal axial gas pressure being exerted about the valve assembly 654, which reduces friction when the movable valve component 657 is actuated between the open and closed positions, which reduces heat at a given speed at which the movable valve component 657 is actuated. This is advantageous when it is desirable to quickly switch a quasi-passive elastic actuator between inelastic and elastic states. This also maximizes or improves the efficiency of the quasi-passive elastic actuator because it reduces the likelihood that the quasi-passive elastic actuator is engaged and disengaged at an improper time that is counterproductive to the actual movement occurring about the joint of the robotic device.

With reference to FIGS. 18A-18D, illustrated is an example valve assembly operable with a first vane device in accordance with another example. In this example, a valve assembly 704 can comprise a valve device 706. The valve device 706 can comprise the same or similar features described above regarding valve device 606, and the valve device 706 can be incorporated into and operable with the first vane device 164 described above (see FIGS. 16A and 16B).

The valve device 706 can be disposed within the opening or bore 277 of the first vane device 164, along the axis of rotation 137 of the robotic joint. In this example, the valve device 706 can comprise a movable valve component 707 coupled to a valve actuator 712, such as by fasteners 705. A first valve body 709 can be coupled to the movable valve component 707, and the first valve body 709 can comprise a spool having an opening 703 that receives and facilitates the coupling of the movable valve component 707. The spool can comprise or can be made of a polytetrafluoroethylene (PTFE) material, or other similar material. Although not meant to be limiting in any way, the movable valve component 707 can be configured as a cylindrical tube with a flange mount, as shown, that is fastened to the valve actuator 712 via fasteners 705.

The valve actuator 712 can comprise a piston 713 and an actuator device 715, such as an arrangement with voice coils. The actuator device 715 can be electrically coupled to a power source and a controller (not shown) to electrically control the actuator device 715 to axially move the piston 713 along the axis of rotation 137, for instance. Therefore, the valve actuator 712 is configured to axially move the coupled movable valve component 707 and the first valve body 709 between the open, partially open, and closed positions (further described below regarding FIGS. 18C and 18D).

The valve device 706 can further comprise a second valve body 717 having a central opening 718 that slidable receives and supports the first valve body 709. The second valve body 717 comprises a first annular channel 711 having a plurality of first openings 723 a formed through the second valve body 717 and disposed or positioned around the first annular channel 711. The plurality of first openings 723 a are each in fluid communication with the second channel 288 b of the first vane device 164 (see FIG. 18C), and the second channel 288 b can be in fluid communication with an expansion gas chamber (e.g., such as expansion chamber 264 b of FIGS. 11A and 11B) via the conduit 290 b of the first vane device 164, as discussed above regarding FIGS. 14A and 14B.

The second valve body 717 comprises a second annular channel 719 having a plurality of second openings 723 b formed through the second valve body 717 and disposed or positioned around the second annular channel 719. The second valve body 717 can comprise interface portions 725 a-c adjacent and separating the respective annular channels 711 and 719, and that are configured to engage and to interface with the inner surface defining the opening 277 of the first vane device 164. Each interface portion 725 a-c can further support one or more seals operable to seal off gasses between the first and second openings 723 a and 723 b. A cap member 735 can be coupled to an end of the second valve body 717 to seal off the inner chamber area of the valve assembly 706.

The plurality of second openings 723 b are each in fluid communication with the first channel 288 a of the first vane device 164 (see FIG. 18C), which is in fluid communication with a compression chamber (e.g., 264 a) via the conduit 290 a, as discussed above.

The first valve body 709 can comprise a first annular stop portion 727 and a second annular stop portion 729 formed on opposing sides of the structure defining the annular passageway 731. The annular passageway 731 can have curved surfaces that extend from respective stop portions 727 and 729 toward a neck portion. The annular passageway 731 can be configured to permit fluid flow between the first and second openings 723 a and 723 b (when in the open or partially open position) of the second valve body 717.

FIG. 18C illustrates the valve device 706 in the open position, specifically showing the movable valve component 707 and the first valve body 709 as retracted by the piston 713, which exposes or uncovers the first and second openings 723 a and 723 b of the second valve body 717. Thus, the first and second openings 723 a and 723 b are in fluid communication with each other about the annular passageway 731 of the first valve body 709, which thereby places the conduits 290 a and 290 b (FIGS. 16A and 16B) in fluid communication, which thereby places the compression and expansion chambers (e.g., 264 a and 264 b) in fluid communication. In this open position, the quasi-passive elastic actuator is caused to enter the inelastic state, wherein pressures within the chambers of the quasi-passive elastic actuator are equalized, as discussed herein. Such open position can occur during free swing mode of a robotic joint, for instance.

Conversely, FIG. 18D illustrates the valve device 706 in the closed position, specifically showing the movable valve component 707 and the first valve body 709 extended by the piston 713 (upon actuation), which position functions to block or cover the first openings 723 a of the second valve body 717. In this position, the second openings 723 b are not in fluid communication with the first openings 723 a of the second valve body 717, thereby restricting fluid flow between the conduits 290 a and 290 b, which thereby restricts fluid flow between the compression and expansion chambers (e.g., 264 a and 264 b, FIG. 11A), such that the quasi-passive elastic actuator is caused to enter the elastic state to store or release energy (depending on the respective gait motion, for instance), as discussed above. Although not shown, the valve device 706 can be positioned in the partially open position to place the quasi-passive actuator in the semi-elastic state.

Notably, the first and second openings 723 a and 723 b are formed radially around the perimeter of the second valve body 717. This configuration provides a radial balance of gas pressure about the valve bodies 709 and 717 because an equal amount of gas pressure is entering the first and second openings 723 a and 723 b around the entire perimeter of the second valve body 717. And, because the first valve body 709 is formed symmetrical along the x plane and along the y plane (FIG. 18A), gas pressure is exerted and balanced radially around the entire perimeter annular passageway 731 (whether the valve is in the open, partially open or closed position). This tends to result in equal radial gas pressure being exerted to the first valve body 709 and the movable valve component 707, which reduces friction when the movable valve component 707 is actuated between the open and closed positions. Providing radial gas pressure balancing can reduce the amount of generated heat at a given speed at which the movable valve component 707 (and the first valve body 709) is actuated.

Furthermore, the valve assembly 704 can be axially gas pressure balanced. That is, the movable valve component 707 can comprise a cylindrically shaped tube body (see FIG. 18A) that has at least one fluid opening 737 in constant fluid communication with chambers on either side of the movable valve component 707, whether in the open, partially open or closed positions (similar in function as the axially balanced principle discussed regarding FIGS. 17A-17E). That is, pressure is equalized axially as the movable valve component 707 is moved between the open and closed positions, which prevents gas pressure from being exerted against the movable valve component 707 in the axial directions during switching the quasi-passive elastic actuator between inelastic and elastic states. As with the radial gas pressure balancing discussed above, this axial balancing tends to result in equal axial gas pressure being exerted about the valve assembly 706, which reduces friction when the movable valve component 707 is actuated between the open, partially open, and closed positions, and which reduces heat at a given speed at which the movable valve component 707 is actuated.

Additional valve assemblies can be incorporated with the quasi-passive elastic actuators discussed herein, such as the various valve assemblies discussed in U.S. patent application Ser. No. 15/810,119, filed Nov. 12, 2017, which is incorporated by reference in its entirely herein.

FIG. 19 is a graph illustrating performance values for joint damping torque vs. various rotary conduit sizes for a quasi-passive elastic actuator corresponding to a knee joint in accordance with an example of the present disclosure. More specifically, in some examples the opening of conduits (e.g., 290 a and 290 b) of a particular first vane device (e.g., 164) can be selected to comprise a particular size to facilitate a damping of a quasi-passive elastic actuator, as exemplified above. That is, by selecting a diameter of the conduits to be in the range of 5-6 mm, for instance, the gas pressure difference between the expansion and compression chambers will result in a joint damping torque of less than approximately 1 N-m, as illustrated, even at the maximum estimated joint speed. This graph pertains to a nominal charge pressure of 1,525 psi in the compression and expansion chambers of the quasi-passive elastic actuator (e.g., having 137 cc), and for a tunable actuator joint module having a torque of 7 N-m/deg. In this example, the outer radius of the quasi-passive elastic actuator is 1.625 in., and the inner radius (defined by the compression and expansion chambers) is 0.78 in., and the cylinder length is 1.5 in. (as defined by the compression and expansion chambers). The first vane device and the second vane device have a volume occupation of 45 deg., and the gas in the compression and expansion chambers is charged at a 90 deg. position of the first vane device relative to the second vane device.

Various slew rates are represented on the graph of FIG. 19 as corresponding to the rotational movement (deg.) of the joint per second. As can be appreciated by the graph, depending on the slew rate, as the conduit diameter increases, the joint damping torque (N-m) decreases. Therefore, a conduit diameter of about 3 mm will provide a greater joint damping torque than one that is 6 mm, for instance. This can be advantageous when designing differing joints, such as a knee joint module as compared to a hip joint module, because inherently lower or higher damping toques would be generated by the selection of the size of the conduit diameter.

Note that spring stiffness is a function of piston/vane and chamber geometries, as well as gas pressure charge. Thus, the magnitude of stiffness for a given joint module is adjustable for mission-specific payloads and terrain-specific gaits while the active valve controls exactly when that stiffness is engaged for energy recovery during the support phase (elastic state) and when it is disengaged during the free swinging state (inelastic state). For instance, the compression and expansion chambers can be selected to comprise a particular volume along with the density of the gas, while the conduits through the first vane device can be selected to corresponding sizes that do not unduly restrict gas flow when in the inelastic state. Also, the particular joint location is determinative of the magnitude of the selected stiffness value. For instance, the charge pressure for a knee joint and the joint speed would both be significantly larger than required from a hip joint.

FIGS. 20A-20F illustrate various aspects of a tunable actuator joint module 800 in accordance with an example of the present disclosure. The tunable actuator joint module 800 can be incorporated into a robotic or robot limb, such as into the exoskeleton robot shown in FIG. 1 or 4A-4B, to provide, for example, an ankle joint defining a flexion/extension degree of freedom, as further discussed below. Alternatively, the tunable actuator joint module 800 can be incorporated into a robot, such as a robot exoskeleton or humanoid robot as an actuator for any joint, such as a knee joint, a hip joint, a shoulder joint, an elbow joint, or others.

Generally, the tunable actuator joint module 800 can comprise an output member 802 a and an input member 802 b that can each be rotatable about an axis of rotation 804 (or rotatable about different axes). The tunable actuator joint module 800 can comprise a primary actuator 806 (e.g., an electric motor, electromagnetic motor, etc.) operable to apply a primary torque to rotate the output member 802 a about the axis of rotation 804. The tunable actuator joint module 800 can further comprise a quasi-passive elastic actuator 808, such as a quasi-passive linear pneumatic actuator as shown, that operates in parallel with the primary actuator 806 in a similar manner as discussed above with respect to the quasi-passive rotary pneumatic actuator. Indeed, the quasi-passive elastic actuator 808 is operable to selectively store energy upon a first rotation or movement of the input member 802 b, and operable to selectively release energy upon a second rotation of the input member 802 b to apply an augmented torque to assist rotation of the output member 802 a, and to minimize power consumption of the primary actuator 806, or to apply a braking force to restrict rotation of the joint, similarly as described above with respect to the quasi-passive elastic actuator 134. The quasi-passive elastic actuator 808 can further comprise an elastic component in the form of a linear pneumatic spring tunable to a desired joint stiffness value, as detailed below.

The input member 802 b can be coupled to a support member of a robotic assembly (e.g., a support member as part of a limb), such as support member 105 c of FIG. 4A. Note that the input member 802 b is shown generically as a pin, but it will be appreciated that the support member 105 c, for instance, can be fastened to either side of the quasi-passive elastic actuator 808 about the location of the illustrated pin. In one example, a trunnion mount can be incorporated to mount the quasi-passive elastic actuator 808 to a support member of a robotic assembly. The output member 802 a can be formed as part of an output device 810 that rotates about the axis of rotation 804, as shown. Alternatively, the output member 802 a can be a separate component coupled to the output device 810. The output member 802 a can be coupled to a support member of a robotic assembly, such as support member 105 d of FIG. 4A. As such, the tunable actuator joint module 800 can define a joint of the lower limb of the robotic exoskeleton corresponding to an ankle joint of an operator.

The output device 810 can comprise a cylindrical gear body 812 having a coupling portion 814 that protrudes or extends from the gear body 812. The coupling portion can comprise a slot 816, and with reference to FIG. 20B, a pin 818 can extend laterally through the slot 816 and can be coupled to the coupling portion 814 for rotatably coupling the quasi-passive elastic actuator 808 to the output device 810, as discussed below. The output device 810 can further comprise a ring gear 820 coupled to the cylindrical gear body 812, and the ring gear 820 can be rotatably coupled to the primary actuator 806 by a transmission belt 822, such that the primary actuator 806 drives the ring gear 820 via the transmission belt 822 to actuate the tunable joint module 800. Note that the transmission belt 822 can be replaced with other types of torque-transmitting devices, such as those discussed above regarding the discussion of belt 224.

Similar to the primary actuators discussed above, the primary actuator 806 of FIG. 20A can comprise a motor 801 and a transmission, such as a planetary transmission 803, operatively coupled to the motor 801. The motor 801 and planetary transmission 803 can have the same or similar structure and functionality as described above regarding the primary actuator of FIG. 9A. A transfer wheel (not show here) can be coupled to a rotor 805 of the motor 801. As with FIG. 9A, the motor 801 can be a frameless brushless electric motor having a stator 807 coupled to a frame or other support structure. The transfer wheel that can be incorporated in FIG. 20A can be similar to the transfer wheel 198 of FIG. 9A, specifically, the transfer wheel can be coupled to the rotor 805 about perimeter fasteners, and the sun gear of the planetary transmission 803 can be coupled to a central opening of the transfer wheel (e.g., FIG. 9A). Thus, upon actuation of the motor 801, the rotor 805 rotates the transfer wheel, which rotates the sun gear of the planetary transmission 803. Upon rotation of the sun gear, the planet gears rotate the carrier, which rotates an output pulley 807 coupled to the carrier of the planetary transmission 803 (such structure and functionality is similarly described regarding FIG. 8A-9B, and will not be discussed in greater detail here). Upon rotation of the output pulley 809, the transmission belt 822 rotates the output device 810, which can rotate the output member 802 a relative to the input member 802 b. Thus, the primary actuator 806 is configured to apply a primary torque to rotate the output member 802 a.

In some examples, as also discussed above regarding belt 224 of FIG. 6A, various other torque-transmitting devices can replace the particular configuration of the belt 822 of FIG. 20A, such as one or more belts or linkages or gears or tendons (or combinations of such), and such alternatives can be arranged to have an axis of rotation that is offset from (e.g., oriented in a direction along a plane that is perpendicular or orthogonal or some other angle other than parallel) to the axis of rotation of the primary actuator 801). And, various transmissions can be arranged to provide different gear reductions from input to output, including a relatively high gear reduction (e.g., 20:1, or more), or a relatively low gear reduction (e.g., 1:1), or any gear reduction between these, depending on the particular application. In some examples, the torque-transmitting device in the form of belt 822, or such various alternative torque-transmitting devices, can allow the primary actuator 801 to be remotely located away from the output (i.e., the primary actuator 801 is located a given distance away from the output of the tunable actuator joint module, but operably connected thereto via the torque-transmitting device), wherein the remotely located primary actuator 801 can be actuated and its torque transferred to the output of the tunable actuatable joint module corresponding to a joint of the robotic system. For instance, the primary actuator 801 could be located at a lower back area of an exoskeleton (e.g., FIG. 4A), while such alternative torque-transmitting device(s) could transfer the primary toque from the lower back area to an output member located in the tunable actuator joint module of the ankle joint for actuating the ankle joint.

The quasi-passive elastic actuator 808 can comprise a housing 824 (e.g., cylinder) that can contain pressurized gas. The housing 824 is supported on either end by a lower seal body 826 a and an upper seal body 826 b formed to seal gas within the housing 824 (see FIG. 20D). A movable piston rod 828 extends through apertures of each of the seal bodies 826 a and 826 b, and through the housing 824 (FIG. 20C). A piston cylinder 830 is coupled to a section of the piston rod 828, and both are linearly movable through and within the housing 824. As shown in FIGS. 20C and 20D, the piston cylinder 830 defines, in part, and divides a compression chamber 832 a and an expansion chamber 832 b within the housing 824. The position of the piston cylinder 830 can be different depending upon the desired performance. In one aspect, the piston cylinder 830 can be positioned such that the compression and expansion chambers 832 a and 832 b comprise equal volumes. In another aspect, the piston cylinder 830 can be positioned such that the compression and expansion chambers 832 a and 832 b comprise disparate or different volumes. The advantages of designing the compression and expansion chambers 832 a and 832 b having disparate volumes are similar or the same as described above with reference to the disparate volumes as described with reference to FIG. 11B. In another example, the piston rod 828 of the quasi-passive elastic actuator 808 can be coupled to an output member via a four-bar linkage configuration.

Seal assemblies can be disposed in each of the upper and lower seal bodies 826 a and 826 b that slidably receive the piston rod 828 while sealing gas within the housing 824. A coupling device 834 can be coupled to a lower end of the piston rod 828, and can comprise an aperture through which the pin 818 (FIG. 20B) extends through to rotatably couple the quasi-passive elastic actuator 808 to the output device 810.

In one example, the tunable actuator joint module 800 comprises a control system for selectively controlling application of the augmented torque of the quasi-passive elastic actuator 808, or the braking force. Specifically, the control system comprises a valve assembly 838 controllably operable to switch the quasi-passive elastic actuator 808 between an elastic state, a semi-elastic state, and an inelastic state (similar to the valve assemblies and quasi-passive elastic actuators discussed above). In this example, the valve assembly 838 comprises a valve device 840 actuatable to allow, partially allow, or restrict/block fluid (e.g., air) flow between compression and expansion chambers 832 a and 832 b. Accordingly, FIG. 20D shows the valve device 840 in the open position that permits the shunting of fluid flow between the compression and expansion chambers 832 a and 832 b, and FIG. 20E shows the valve device 840 in the closed position, wherein fluid flow between the compression and expansion chambers 832 a and 832 b is restricted. Thus, the valve device 840 defines or comprises a shunt circuit that facilitates fluid flow between the compression and expansion chambers through the valve assembly. Although not shown, the valve device 840 can be positioned in the partially open position to place the quasi-passive actuator 808 in the semi-elastic state

Specifically, the valve device 840 can comprise a movable valve component 841, a piston 843, and an actuator 845 (e.g., a voice coil), similar to the valve device of FIG. 17C. The movable valve component 841 can be coupled to the piston 843 via one or more fasteners (e.g., fastener 847). The actuator 845 can be supported and housed by a cap member 849 coupled to the upper seal body 826 b to partially house the valve assembly 838. Therefore, upon supplying an electrical field to the actuator 845, the piston 843 moves the movable valve component 841 between the open position (FIG. 20D), the partially open position, and closed position (FIG. 20E).

The valve assembly 838 can comprise a valve body 842 generally cylindrical and tubular in shape, and supported in a chamber of the upper seal body 826 b. The valve body 842 can be similar to the valve body 659 of FIG. 17C, such that the valve body 842 comprises an annular passageway 844 formed annularly around a middle perimeter section of the valve body 842. The valve body 842 further comprises a plurality of openings 846 (one labeled) formed radially around the valve body 842 proximate the annular passageway 844. Thus, the movable valve component 841, being slidably interfaced to an inner surface of the valve body 842, can be axially moved to at least partially uncover the plurality of openings 846 (FIG. 20D) in the open and partially open positions, and moved to cover the plurality of openings 846 (FIG. 20E) in the closed position.

In this manner, the quasi-passive elastic actuator 808 can comprise a tube 848 coupled between the upper and lower seal bodies 826 a and 826 b (FIG. 20C). The tube 848 can comprise a first conduit 850 in fluid communication with a passageway 852 (FIG. 20F) formed through the lower seal body 826 a. The passageway 852 extends through the lower seal body 826 a, and is in fluid communication with the expansion chamber 832 b, as shown by the dashed arrows showing the gas flow path. The first conduit 850 is further in fluid communication with a valve chamber 854 defined by the movable valve component 841 and the valve body 842 (FIG. 20D). The upper seal body 826 b comprises a second conduit 856 in fluid communication with the compression chamber 832 a, and in selective fluid communication with the annular passageway 844 of the valve body 842 (and consequently in fluid communication with the internal chamber 854). Thus, when in the open position of FIG. 20D, or partially open position, a gas flow path exists between the compression and expansion chambers 832 a and 832 b about the first conduit 850, the internal chamber 854, the plurality of openings 846, the annular passageway 844, and the second conduit 856, as shown by the dashed arrows on FIGS. 20D and 20F. Conversely, when in the closed position of FIG. 20E, such fluid path is closed off by the movable valve component 841 upon actuation of the movable valve component 841 to cover the plurality of openings 846. This two-way valve function therefore facilitates the selective engaging, semi-engaging and disengaging of the quasi-passive actuator for the purposes described herein.

In one example, the housing 824 may not be gas pressure charged and is at ambient gas pressure, such that the stiffness value of the tunable actuator joint module 800, and particularly the quasi-passive elastic actuator, is near ambient gas pressure. In another example, the housing 824 can be gas pressure charged and tuned to define a predetermined gas pressure (e.g., 500-3000+psi) to define a given joint stiffness value, similar to that described above regarding the rotary pneumatic actuators. This pre-charged gas pressure can be achieved during manufacture, or in the field by a user (e.g., via a gas pressure source and valve, not shown). And, such pre-charged gas pressure can be dynamically modified (increased or decreased) by adding or relieving gas pressure in the housing 824 via a valve, for instance. This is another example of what is meant by the term “tunable” actuator joint module, because the example actuator joint module 800 can be tuned to have a particular joint stiffness value by selecting the amount of gas pressure charged in (or removed from) the compression and expansion chambers.

The control system, including the valve assembly 838, can further comprise a computer system (not shown) having a controller electrically or communicatively coupled to the valve assembly 838 (i.e., to the actuator 845) to apply an electrical field to control operation of the actuator 845 and the valve assembly, thereby switching the valve device between the open, partially open and closed positions. The computer system can be coupled to a power source, such as to a battery onboard the robotic device (e.g., in a backpack) or to another power source associated with the robot or robotic device.

In operation, upon a first rotation of the input member 802 b relative to the output member 802 a (e.g., such as during a first segment of a walking or running gait cycle), and when the valve device 838 is in the closed position, the piston rod 828 and the piston cylinder 830 move upwardly relative to the housing 824, which functions to store gas pressure energy about the compression chamber 832 a. Upon a second rotation of the input member 802 b relative to the output member 802 a (e.g., such as during a second segment of the gait cycle), this stored energy can be released when gas pressure exerted against the piston cylinder 830 is allowed to expand, which causes an axial biasing force to the piston rod 828, which exerts an augmented torque to the output device 802 a to rotate the output member 802 a of the output device 810 in parallel with the primary torque being applied by the primary actuator 806. This action can also be used to generate and apply a braking force to restrict rotation of the input member 802 b relative to the output member 802 a. Upon a third rotation of the input member 802 b relative to the output member 802 a (e.g., during a swing phase of the gait cycle), the valve device 838 can be actuated to the open position, which equalizes pressure between the compression and expansion chambers 832 a and 832 b, and which facilitates the shunting of fluid between these two chambers, thus placing the quasi-passive actuator in the aforementioned free swing or inelastic mode. In this mode, negligible resistance exists about the tunable actuator joint module 800 upon such third rotation of the input and output members 802 a and 802 b.

Therefore, in a practical example (and similar to the above discussion regarding the tunable actuator joint module 109 a), where the tunable actuator joint module 800 is incorporated into an ankle joint of a robotic assembly (e.g., exoskeleton joint 101 of FIG. 4A) to provide a flexion/extension degree of freedom, upon a first gait movement (e.g., shortly after heel strike) the valve device 838 is controlled to be in the closed position, thereby facilitating storage of energy about the quasi-passive elastic actuator 808, as discussed above. And, upon a second gait movement (e.g., after heel strike and before toe-off) the valve device 838 is maintained in the closed position to facilitate the release of stored energy to apply the augmented torque to the primary torque to actuate the ankle joint, as discussed above. As is specifically discussed above, upon such second gait movement, the primary actuator 806 can be actuated to apply a primary torque, along with the augmented torque applied by the quasi-passive elastic actuator 808, to rotate the output member 802 a, as coupled to a support member of a robotic assembly. Finally, upon a third gait movement (e.g., just before toe-off) the valve device 838 is actuated to the open position, as discussed above, to facilitate free swing of the ankle joint. Various movements can also be braked by operating the quasi-passive elastic actuator to apply a braking force.

In one specific example, the housing 824 can comprise a 155 cc volume, with the compression volume being 56 cc, and the expansion volume being 99 cc (the compression and expansion chamber volumes being disparate as defined by the positioning of the piston). The housing 824 can be charged to 1003 psi, with a 1577 peak psi at 20 degrees compression, which produces a 526 N-m torque. The piston rod 828 diameter can be 0.3125 inches and the piston cylinder 830 1.75 inches. This can provide approximately 25 N-m/degree joint stiffness value for a knee or ankle joint, for instance. This example is not intended to be limiting in any way as will be apparent to those skilled in the art.

Note that the quasi-passive elastic actuators discussed herein (i.e., rotary and linear) can be charged with a two-phase fluid. For instance, a quasi-passive elastic actuator can be pressure charged with a fluorocarbon or fluorocarbon refrigerant (e.g., Freon), which can initially be in a gaseous state when the quasi-passive elastic actuator is pre-charged or in a nominal position, wherein upon pressure or compression of the gas inside the compression chamber (due to rotation of the joint), the gaseous fluid can transition to a liquid state. This provides the tunable actuator joint module with the advantageous properties of a liquid under compression, as compared to a gaseous fluid, which can enhance the stability of the system.

In one example, the combined output torque (i.e., the primary torque combined with the augmented torque) provided by the tunable actuator joint module 800 can be selected to be a predetermined output torque. In one aspect, this can be based on the selected position of the coupling between the piston rod 828 and the output member 802 a. For instance, as shown in FIG. 20A the piston rod 828 can be coupled to the output device 810 at an off-center position relative to the axis of rotation 804, and at a predefined distance from the axis of rotation 804, and also optionally at a predefined angle.

In an alternative example, a single-rod linear pneumatic spring can be incorporated. For instance, piston rod 828 would not extend through a top of the housing 824, and instead it would terminate at the piston cylinder 830. In this manner, such piston cylinder could be originally positioned in the housing at a middle area such that the compression and expansion chambers have equal volume, or positioned away from the middle area of the housing to provide disparate volumes of the compression and expansion chambers.

As indicated above, in examples where a particular tunable actuator joint module discussed herein is incorporated as a joint in an upper body exoskeleton, the quasi-passive elastic actuators can provide a gravity compensation function, such as when arms are raised to support body armor and/or weapons. That is, when the arm is raised while supporting a load, the quasi-passive elastic actuator can be operable to apply an augmented torque to resist the forces of gravity acting on the load and to assist in lifting the load. In examples where a particular tunable actuator joint module as discussed herein is incorporated as a joint of a lower body exoskeleton, the tunable actuator joint module can be designed for a maximum torque of 250 N-m, while the quasi-passive elastic actuator can be designed for a 7 N-m/degree spring stiffness value for a knee joint, and a 3 N-m/degree for a hip joint, for instance. Because cyclic gaits such as walking typically do not exceed 20 degrees, the total torque provided by a lower body tunable actuator joint module can be approximately 140 N-m in normal operation.

FIG. 21 illustrates a quasi-passive elastic actuator 900 that can be coupled remotely away from an ankle joint rotation 902, for instance. The quasi-passive elastic actuator 900 can have the same or similar features as that of the quasi-passive elastic actuator 808 discussed above, such as having a control system, including the valve assembly 838. In this example, the quasi-passive elastic actuator 900 can be remotely coupled anywhere along a support member of a robotic system (such as an exoskeleton, humanoid or other robotic system as contemplated herein). For example, the quasi-passive elastic actuator 900 can be remotely coupled to a support member 904 corresponding to a femur of an operator wearing an exoskeleton, therefore being positioned distally away from the axis of rotation of the output member. As in the example shown, a Bowden cable 906 (or other similar semi-flexible force transmitting device, or other transmission device) could be coupled between a piston cylinder 908 of the quasi-passive elastic actuator 900 and an output member 910 associated with the ankle joint 902 for actuating the ankle joint 902 to move an ankle support member 912 on which the operator's foot is supported. In one aspect, being “remotely located” can mean that at least one joint (e.g., the knee joint 914) is disposed or positioned between the quasi-passive elastic actuator 900 (the device storing energy and releasing energy to apply a torque) and the joint associated with the quasi-passive elastic actuator 900 that is to be actuated, which is the ankle joint 902 in this example. In some examples, a primary actuator (e.g., motor) can be coupled adjacent the quasi-passive elastic actuator 900 (e.g., coupled to support member 904) and to the Bowden cable 906 to apply a primary torque via the Bowden cable 906 to actuate the joint, in this case the ankle joint 902. Alternatively, the primary actuator can be coupled locally, such as at or near the joint (e.g., the ankle joint 902) to apply a primary torque (whether in parallel or series) along with the augmented torque applied by the quasi-passive elastic actuator 900.

In operation, using the example arrangement shown, upon a first rotation of the ankle joint 902 (i.e., just after heel strike during stance compression) the quasi-passive elastic actuator 900 is operable to store energy when operated in an elastic state (because the piston cylinder 908 is moved upwardly though a housing to store energy in a compression chamber, similarly as discussed regarding quasi-passive elastic actuator 808). And, upon a second rotation of the ankle joint 902 (i.e., after heel strike and up to toe-off during stance extension), the quasi-passive elastic actuator 900 is operable to release the stored energy, when operated in the elastic state, to apply a torque (e.g., augmented with a primary torque in one example) to actuate the ankle joint 902 via the Bowden cable 906. Optionally, during a third rotation (i.e., from toe-off to heel strike), the quasi-passive elastic actuator 900 can be switched (via a valve) to operate in an inelastic state, such that no energy is being stored or released via the quasi-passive elastic actuator 900, thereby allowing the ankle joint 902 to be in a free-swing mode.

The quasi-passive elastic actuator 900 is shown as comprising an elastic component in the form of a linear pneumatic spring, but alternatively can be a rotary pneumatic spring (such as exemplified herein), or even a mechanical spring, such as a coil spring, polymer spring, torsional spring, or other elastic component.

Remotely locating the quasi-passive elastic actuator, by itself or with one or more additional components of the tunable actuator joint module, can remotely place the mass of the quasi-passive elastic actuator 900 (and perhaps a primary actuator) closer to the center of gravity of the robotic system (e.g., closer to the center of gravity of an exoskeleton and an operator of the exoskeleton), which can reduce the moment of inertia during joint rotation (e.g., gait movements), which thereby further reduces or minimizes the power dissipation required to actuate the joint. Therefore, the quasi-passive elastic actuator 900 (and optionally a primary actuator) can be sized smaller than normally required when located locally near the joint.

The tunable actuator joint modules discussed herein can be controlled by a controller of a computer system, whether located on-board of the robot or robotic device or remotely located such that the robot or robotic device is in communication with the computer system using known communication techniques and methods. In addition, the controller can be used to control each of the tunable joint actuator modules in a robot or robotic device, and to operate these in a coordinated manner (e.g., within a robotic exoskeleton, operate a tunable actuator knee joint module with that of a tunable actuator hip module or tunable actuator ankle module, such that each of these functions with the other to provide human kinematic equivalent motions, such as during walking, running, squatting, or other movements). For example, assume a lower body exoskeleton is worn by a human operator during a running gait cycle, and assume left/right ankle joints each include the tunable actuator joint module 800, and left/right knee and hip joints each include a tunable actuator joint module (109 a, 130, or 500), discussed in detail above. The computer system can receive position and force data from position or force sensors, or both, associated with each of said tunable actuator joint modules. The position and force data can be processed to generate information that determines the particular respective positions of each of said tunable actuator joint modules, or the forces acting thereon, and one or more gait recognition algorithms can process such information to determine which (if any) of said tunable actuator joint modules are to switch between elastic, semi-elastic and inelastic states. Accordingly, the computer system can generate and transmit command signals to respective tunable actuator joint module(s) to actuate the respective valve assemblies to the appropriate open or closed positions, and/or to actuate respective electric motors to apply a primary torque. Such processing can be performed in milliseconds and on a continuous basis during the gait cycle, for instance, for every tunable actuator joint module. The same holds true for task-specific movements, such as walking, jumping, squatting, climbing or other movements.

It is further noted that rotation of the joints (i.e., relative rotation between the input and output members) defined by the various tunable actuator joint modules discussed herein can be in any direction (e.g., the same direction, different directions) during the storing and releasing of the energy, during the generation and application of a braking force, as well as the opening of the valve assemblies and the shunt circuits to facilitate free swing of the joints. In other words, the valve assemblies can be operated to engage to store energy, to release energy, or to disengage to facilitate free swing of the joint upon rotation of an associated joint in the same direction or in various different directions. This is the case for all of the examples set forth in the present disclosure.

It is to be understood that the embodiments of the invention disclosed are not limited to the particular structures, process steps, or materials disclosed herein, but are extended to equivalents thereof as would be recognized by those ordinarily skilled in the relevant arts. It should also be understood that terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting.

Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment.

Although the disclosure may not expressly disclose that some embodiments or features described herein may be combined with other embodiments or features described herein, this disclosure should be read to describe any such combinations that would be practicable by one of ordinary skill in the art. The user of “or” in this disclosure should be understood to mean non-exclusive or, i.e., “and/or,” unless otherwise indicated herein.

As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary. In addition, various embodiments and example of the present invention may be referred to herein along with alternatives for the various components thereof. It is understood that such embodiments, examples, and alternatives are not to be construed as de facto equivalents of one another, but are to be considered as separate and autonomous representations of the present invention.

Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the description, numerous specific details are provided, such as examples of lengths, widths, shapes, etc., to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

While the foregoing examples are illustrative of the principles of the present invention in one or more particular applications, it will be apparent to those of ordinary skill in the art that numerous modifications in form, usage and details of implementation can be made without the exercise of inventive faculty, and without departing from the principles and concepts of the invention. Accordingly, it is not intended that the invention be limited, except as by the claims set forth below. 

What is claimed is:
 1. A robotic system for a robotic limb configured to recover energy for minimizing power consumption of the robotic system, comprising: a plurality of support members; and at least one tunable actuator joint module rotatably coupling two of the plurality of support members, the at least one tunable actuator joint module defining a joint of the robotic system rotatable about an axis of rotation, and comprising: a primary actuator operable to apply a primary torque to cause actuation of the joint; and a quasi-passive elastic actuator comprising an elastic component dynamically tunable to a joint stiffness value, the quasi-passive elastic actuator operable to store energy upon a first rotation of the joint, and to release energy upon a second rotation of the joint to apply an augmented torque to the joint that combines with the primary torque from the primary actuator to assist rotation of the joint, wherein the quasi-passive elastic actuator comprises a rotary pneumatic actuator, and the elastic component comprises a housing that is gas pressure charged to a selected gas pressure to define a predefined joint stiffness value, a first vane device coupled to a first support member and a second vane device coupled to a second support member, the first vane device and the second vane device defining a compression chamber and an expansion chamber within the housing, and wherein the first vane device is rotatable relative to the second vane device about the axis of rotation, wherein upon a first rotation gas is compressed in the compression chamber between the first vane device and the second vane device to store energy, such that, upon a second rotation, gas is expanded in the compression chamber to release the stored energy to apply the augmented torque to assist in actuation of the joint.
 2. The robotic system of claim 1, further comprising a control system operable to facilitate selective control and application of the augmented torque.
 3. The robotic system of claim 2, wherein the control system comprises a valve assembly operable to switch the quasi-passive elastic actuator between an elastic state, a semi-elastic state, and an inelastic state, wherein in the elastic state, the quasi-passive elastic actuator operates to store and release the energy, wherein in the semi-elastic state, the quasi-passive elastic actuator operates in a damping mode, and wherein in the inelastic state, the quasi-passive elastic actuator operates in a free-swing mode.
 4. The robotic system of claim 3, wherein the quasi-passive elastic actuator comprises a compression chamber and an expansion chamber, and wherein the valve assembly and the elastic element define a shunt circuit that facilitates fluid flow between the compression and expansion chambers through the valve assembly.
 5. The robotic system of claim 1, wherein the elastic component comprises a housing, at least a portion of which is operable to be charged to a selected gas pressure to define a predefined joint stiffness value.
 6. The robotic system of claim 1, wherein the first vane device is positioned 180 degrees from the second vane device in a nominal position, such that the compression and expansion chambers comprise substantially equal volumes.
 7. The robotic system of claim 1, wherein the first vane device is positioned greater or less than 180 degrees from the second vane device in a nominal position, such that the compression and expansion chambers comprise disparate volumes.
 8. The robotic system of claim 1, wherein the rotary pneumatic actuator and the primary actuator each have a central axis of rotation parallel to each other.
 9. The robotic system of claim 1, wherein the primary actuator comprises a transmission operatively coupled to the primary actuator, wherein a torque-transfer device rotatably couples the primary actuator and the rotary pneumatic actuator.
 10. The robotic system of claim 1, further comprising a valve device of a valve assembly disposed through an opening of the first vane device, wherein the valve device is controllable to open and close a shunt circuit and to switch the quasi-passive actuator joint module between the elastic and inelastic states.
 11. The robotic system of claim 10, wherein the valve device comprises an axis collinear with the axis of rotation of the tunable actuator joint module.
 12. The robotic system of claim 1, wherein the at least one tunable actuator joint module further comprises an output device comprising an output member and a gear ring, wherein the primary actuator comprises an output pulley, wherein the output pulley and the gear ring are rotatably coupled by a torque-transfer device.
 13. The robotic system of claim 12, wherein the housing of the linear pneumatic actuator is coupled to the input member, wherein the piston rod is coupled to the output member at an off-center position relative to the axis of rotation, such that rotation of the input member causes the piston cylinder to linearly move upon the first rotation to selectively compress gas in the compression chamber to store energy.
 14. The robotic system of claim 12, wherein the output member comprises an output pulley member rotatably coupled to the primary actuator by a torque-transfer device.
 15. The robotic system of claim 1, wherein, upon the second rotation, the linear pneumatic actuator releases energy via the piston rod to apply the augmented torque to the output device in parallel with the primary torque applied by the primary actuator.
 16. The robotic system of claim 1, wherein the primary actuator comprises a motor and a transmission operatively coupled to the motor, and wherein the transmission is at least partially disposed within a central void of the motor.
 17. The robotic system of claim 1, wherein the robotic limb comprises a lower robotic limb, wherein the at least one tunable actuator joint module corresponds to one of a hip joint, a knee joint, or an ankle joint, wherein the at least one tunable actuator joint module is operable to selectively apply the augmented torque in parallel with the torque applied by the respective primary actuator during a gait-like movement of the lower robotic limb.
 18. The robotic system of claim 1, wherein the quasi-passive elastic actuator is coupled to one of the support members, and positioned remote from the axis of rotation.
 19. A robotic system for a robotic limb configured to recover energy for minimizing power consumption of the robotic system, comprising: a plurality of support members; and at least one tunable actuator joint module rotatably coupling two of the plurality of support members, the at least one tunable actuator joint module defining a joint of the robotic system rotatable about an axis of rotation, and comprising: a primary actuator operable to apply a primary torque to cause actuation of the joint; and a quasi-passive elastic actuator comprising an elastic component dynamically tunable to a joint stiffness value, the quasi-passive elastic actuator operable to store energy upon a first rotation of the joint, and to release energy upon a second rotation of the joint to apply an augmented torque to the joint that combines with the primary torque from the primary actuator to assist rotation of the joint, wherein the quasi-passive elastic actuator comprises a linear pneumatic actuator, and the elastic component comprises a housing that is gas pressure charged with a selected gas pressure to define a predefined joint stiffness value, a piston rod and a piston cylinder linearly movable in a linear motion within the housing, wherein the piston cylinder defines, at least in part, a compression chamber and an expansion chamber within the housing, wherein the linear pneumatic actuator comprises an input member, and wherein the piston rod is pivotally coupled to an output device at an off-center position, such that, upon the first rotation, movement of the input member causes the piston cylinder to move to compress gas in the compression chamber to selectively store energy.
 20. A robotic system for a robotic limb configured to recover energy for minimizing power consumption of the robotic system, comprising: a plurality of support members; and at least one tunable actuator joint module rotatably coupling two of the plurality of support members, the at least one tunable actuator joint module defining a joint of the robotic system rotatable about an axis of rotation, and comprising: a primary actuator operable to apply a primary torque to cause actuation of the joint; and a quasi-passive elastic actuator comprising an elastic component dynamically tunable to a joint stiffness value, the quasi-passive elastic actuator operable to store energy upon a first rotation of the joint, and to release energy upon a second rotation of the joint to apply an augmented torque to the joint that combines with the primary torque from the primary actuator to assist rotation of the joint, wherein the quasi-passive elastic actuator comprises a linear pneumatic actuator, and the elastic component comprises a housing that is gas pressure charged with a selected gas pressure to define a predefined joint stiffness value, a piston rod and a piston cylinder linearly movable in a linear motion within the housing, wherein the piston cylinder defines, at least in part, a compression chamber and an expansion chamber within the housing, wherein the linear pneumatic actuator comprises an input member, wherein the piston rod is pivotally coupled to an output device at an off-center position, such that, upon the first rotation, movement of the input member causes the piston cylinder to move to compress gas in the compression chamber to selectively store energy, and wherein the at least tunable actuator joint module further comprises an output device comprising an output member and a gear ring, wherein the primary actuator comprises an output pulley, wherein the output pulley and the gear ring are rotatably coupled by a torque-transfer device. 